I just purchased my first 3d printer off Amazon. It is a JGAurora Z-603s printer and i like it so far, but I am one of those people that can't leave things alone. I see lots of mods in its future, as i tend to hack everything I own.

Anyhow, I had a gear that was broken that controls the blend door on my International Prostar (floor-vent-defrost control). It is exactly the same motor that is in a jeep Cherokee, and I can get the entire controller motor for about $45 bucks form the auto parts store, but I thought it would be a cool first project for my printer instead. I attached some pics of the broken gear, etc.

It presented a challenge as there is a spindle on both sides of it, making my printer to have to bridge build the gear itself,.. and I did not like that. What I did was to make it in two pieces instead, and make it "snap" together. Also, the teeth are quite fine on it with a tip width of only 0.3mm A challenge for any 3d printer to get right.

I decided to make the gear out of PTEG for now, and will try to print it with other materials as a test part just to see how it will come out with different materials, but that is for another time.

I attached some some pics of the broken part/gear and the new one. I made the drawing in blender and exported it as an .STL file to Cura and printed it up. It printed great and it works as well, if not better than the old one worked. My A/C works like new again.