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A2
Tks for the update, the cast parts look good.
What resin are you using, it would be visually interesting to cast it clear, the white parts look stylish.
If you plan to advertise your printer, black is the worse color (magazine editors don't like it, and even forbid it), white, and bright colors show off the product best.
If the resin is rubbery, you might need to add a filler (glass fibers) to the worm wheel to stiffen up the cast part.
Maybe a filler will help with the geometry issues too.
I've used glass micro spheres in epoxy, it makes it brittle.
For structural strength cotton flock is added to epoxy, I've seen it used on kit planes.
I am using an epoxy resin and aluminum hydrate as a filler and to help prevent shrinkage. Cotton flock and fiberglass can make it difficult to pour the epoxy and fill the mold if the fibers are too long. I have some very short 1/32" milled fiberglass but that tends to make the epoxy brittle as well. If the strength of the casts become an issue I may test 1/16" length fibers. Also the colorant is powdered tempura paint.
Jon @ Solidus Labs