Bosch Classic eBike Gear

thingiverse

The critical plastic gear of my first-generation Bosch ebike motor broke (see attached picture). Without a spare part available, I chose to design and create a replacement by myself. The original gear is crafted from a single piece of plastic that encases the axle. In contrast, my version requires two separate components: one for the gear itself and another to secure it on the axle in precisely the right position. Six 12mm long screws with 3.5mm countersunk heads are needed to connect these two parts together. I produced the new gear using a PETG material. The printing settings included: - A layer height of 0.2mm for optimal precision - A scale factor of 1.0045 to compensate for the shrinkage inherent in the PETG material - Seven perimeter shells for enhanced structural integrity - 50% infill for added strength and durability Since this is a brand-new part, I have no information on its long-term durability.