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I wonder if using a metal gear instead would destroy the other plastic gears?
Oddly enough, it's often the other way around. Hard oxide particles stick in the softer material of an unmatched pair and erode the harder material. This is how lapping works. Nylon bushings have been known to wear hardened steel shafts to the point of failure with negligible wear of the bushing. Not that you should worry too much in this case. Nylon or Delrin (acetal) gears are mostly used because they are cheap, not because they are otherwise preferable to metal ones.
Since the jumps between different gear moduli are quite large, you can almost certainly guess what you need simply from counting teeth and measuring OD. The most important thing is finding a stock solution, since having gears made is unlikely to be economically worthwhile.
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gbj_tester
@psg1ben
Thanks @freezing77 @Brun @hiraethus
I spent that day trying to guess/eyeball a pressure angle and making something in a web based CAD (from my phone which was a nightmare) both a bit of a flop.
I was just trying to look for a lazy solution where I could send it off for a copy.
It's from a salvaged motor so I'm willing to put some money into it. I'm also maybe willing to try a slightly wrong (material/size) gear and risk destroying it even more, it can go back in the bin.
I wonder if using a metal gear instead would destroy the other plastic gears?
Sounds like a subtractive process might be more applicable than 3d printing for a plastic gear.