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Re: New arm design for Simpson style printer.

A2: I am sure that is just a mockup but just in case I want to say that a herringbone like arrangement of the gears or some other alignment scheme is needed to keep the arms from shifting in the axial direction.

Your mockup reminded me that cycloidal gears also could be fun to play around with. The beauty of cycloidal gears is that it is all rolling contact instead of sliding contact.
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Situations like this...
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... make it unsuited for power transmission or even for this rolling contact situation. However, using a cycloidal profile combined with a herringbone arrangement should prevent the situation above. I think it would be better suited to 3D printing than an involute profile.

I will be curious to see if you can tension using your procedure above. It sounds promising.

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