pic: Custom Machined Aluminum #25 Sprocket

[Holtzman]

Yes, the teeth were milled. Off the top of my head, I believe these are the operations we performed. It was a couple of months ago so the feeds and speeds might not be 100% accurate.

5/8" roughing endmill 1000rpm 4"/min roughs out tooth face and bore
1/2" ball nose endmill 1200rpm 2"/min put radius' around bolt holes
1/4" roughing endmill 1800rpm 2"/min roughs out medium sized pockets
1/4" plain endmill 2000rpm 6"/min finishes medium sized pockets and bearing bore.
1/8" plain endmill 2500rpm 1.25"/min mills small pockets, spot drills bolt holes, and outside sprocket teeth.

CAD files are available for anyone who wants them. As for FEA, if anyone wants to do it, go nuts.