Hi Tony,

Do you use Cura?

I found that a combination of negative 'horizontal expansion' with an even greater level for the first layers to prevent elephant's foot is the solution. You will then find all your less critical prints are better too!

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I have horizontal expansion at -0.05mm with initial layer at -0.15mm, that might be a place to start. Also beware worn nozzles!

Neil

Edited By Neil Wyatt on 09/04/2020 12:20:17

Since you now have a 'spare' you might try running it in with a metal gear and see if it improves, or degrades, the tooth face. I printed a module 1 gear, photo in my album, which is fine as a changewheel but I think the requirements are more difficult for a clock.

Another item to consider is the extruder temperature. Not all PLA works well at the same temperature.

Ive seen your gears Dan – good work. I note that you were running with ABS. I tried and it eas a total failure but now ger great results on PLA at very 'loose' setting of 0.3 layer, 10% fill and 205 deg, running at 80mm/s…..i think it runs well because theere is less heat store…keep posting!

I think I've spent 90% of my 3D printer activity on making experiments and 10% on making anything useful.