I was using my Mill and all of a sudden I was taking to big of a cut with my fly cutter and my plastic gear stripped #209. So I decided to create a gear in sketchup per the specs of the Grizzly gear and print it out just to see if it was possible. Well it is possible and it did work quite well until I when to Hi Speed and ultimately thermal meltdown occured. I have since used ABS and it works fine but I am sure a Nylon with Carbon Fiber would work the best.
Using ABS I have had to throw it on the lathe to expand the center part to fit on the spindle but it still works. Hoss is a god in this realm and plan on converting to a belt driven headstock in the future to remedy all issues with using plastic gears.
This is a temp replacement if you use PLA and a longterm replacement if you use ABS, Nylon, or Carbon Fiber filament.