Wow, awesome modelling and design work. I will, however, be surprised if everything can actually hold up. Some of the shocks a board experiences when hitting bumps or gaps in the road/path are pretty extreme. If they can crack aluminium and bend steel, ABS is gonna have a hard time I reckon. How are you stopping the motor mount from swinging around the hanger/axle?
I also suspect that the ABS wheel sprocket may wear quickly, since ABS has pretty bad wear characteristics. I have to recommend Taulman 910 nylon for this application, I've used it to successfully print wheel sprockets for my Evolve, where I just cloned and optimised the OEM design for 3D printing, even though the design needs reinforcement with nails because of the narrow bosses which interface with the Kegel wheels. The belt teeth have been exceptionally wear resistant, with seemingly less wear over time than the OEM part, which I believe is molded polyacetyl. I suspect that the nylon belt facing wears very well against the nylon 910. There's also little dust, I think less than before. I've used them for easily 500 km, or about 2 million rotations, with negligible wear on the teeth. Mine have to be replaced because the bearing seat in them widens and the sprocket goes crooked, but that's a consequence of the Evolve design where the sprocket has a bearing and doesn't screw into the wheel (bad idea IMO, the axle has to be really long and it gets bent easily).
My next goal is actually to test spur gears made from 910, so that the wearing parts of the drivetrain can be printed entirely, instead of still having to buy belts. I also don't like how belts can fail catastrophically with little warning, so I'd like to experiment with gears. I know that there are some disadvantages with gears like the possibility of rocks getting wedged in there or maybe increased wear, but they will be so cheap to print and easy to change. I'm also looking forward to the gear whine. The pitch is a nice speedometer, and the loudness lets you know the torque!
I also suspect that the ABS wheel sprocket may wear quickly, since ABS has pretty bad wear characteristics. I have to recommend Taulman 910 nylon for this application, I've used it to successfully print wheel sprockets for my Evolve, where I just cloned and optimised the OEM design for 3D printing, even though the design needs reinforcement with nails because of the narrow bosses which interface with the Kegel wheels. The belt teeth have been exceptionally wear resistant, with seemingly less wear over time than the OEM part, which I believe is molded polyacetyl. I suspect that the nylon belt facing wears very well against the nylon 910. There's also little dust, I think less than before. I've used them for easily 500 km, or about 2 million rotations, with negligible wear on the teeth. Mine have to be replaced because the bearing seat in them widens and the sprocket goes crooked, but that's a consequence of the Evolve design where the sprocket has a bearing and doesn't screw into the wheel (bad idea IMO, the axle has to be really long and it gets bent easily).
My next goal is actually to test spur gears made from 910, so that the wearing parts of the drivetrain can be printed entirely, instead of still having to buy belts. I also don't like how belts can fail catastrophically with little warning, so I'd like to experiment with gears. I know that there are some disadvantages with gears like the possibility of rocks getting wedged in there or maybe increased wear, but they will be so cheap to print and easy to change. I'm also looking forward to the gear whine. The pitch is a nice speedometer, and the loudness lets you know the torque!
