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I'd be interested to know how well layers of 3d printing holds up to that much rotational mass, lateral forces, and vibration at freeway speeds. I have my doubts at this point of its feasibility.


A 3D printer could be used to create the mold for the rubber perhaps.


You can easily do a lost-wax process with a 3D printer.

(Although getting the precision may be difficult.)


Some folks have already moved on to a lost PLA casting process. I've seen some pretty decent results.

http://3dtopo.com/lostPLA/




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