We had a problematic diamond saw in my lab, it needed some board level repair and a gear replacement. Spare MOSFETs are easy to find but custom gears can be harder.
The saw in question was an old Allied TechCut model, someone else had done electronic repairs on it before but this was its first gear trouble.
The original composite gear had worn down and I wasn't able to locate a replacement.
I prepared a CAD model and printed it in UV resin, however that wasn't durable enough for use on its own.
I used the printed gear and OOMOO30 to make a reusable silicone mold and cast the replacement gear out of epoxy mixed with aluminum powder.
The addition of aluminum makes the epoxy stronger, less brittle, and even machinable. It was a perfect replacement.
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