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Ah. Posted this without a browser refresh . Then saw your post Greg.

You may want to check off reapply features in the circular pattern.

I also eliminated the sketch circular array. Better as a feature pattern of the sweep. More efficient.

Used an actual curve instead of a bunch of lines, much more effective and smoother curve with less control points to form tooth.

https://cad.onshape.com/documents/2aa4d8be793100e5fa95fbf3/w/3a7c3fa108289bbe811a4c08/e/b8cdfef91bbca1c38a6c0c07

Thanks so much for taking the trouble to figure it out! Very grateful for all the detailed feedback. I'm learning a lot and my issue is solved 👍️

It seems absurd to me to let regulations drive such a decision vs choosing the best tool for the goal. Rating compliance above future applicability (which is what teaching is all about) is just well frustrating. If onshape is determined to be the best tool to use...To serve the students the best we should find alternatices to the limitations like compliance. Lil vent from me as I know all to well the limitations placed on me by a public highschool when they place priority on liabilities vs productivity and growth. 😡

The requirement for feature trees is because we need to have something available for remarking. We don't just mark the final output, we also mark processes. If the student appeals anytime in 365 days, then we need to provide the original work to be remarked by an impartial person. If the teacher is no longer at the school (for instance if the assignment is at the end of a term, and a teacher leaves after marking), then the school needs access to remark. If the student still appeals, then it gets sent to the board for review.

You are correct that the free educational edition is not suitable for this. I will advise the QLD ITD forum of your reply so we can transition to Autodesk Fusion. I appreciate your reply.

Hi Tim,

this is already an improvement.
Just use the 'add' tab in the circular pattern. no need for an additional boolean feature.

else use @GregBrown's featurescript called Auto-boolean.

In this case though, if you still want to add fillets etc, you shouldn't have to do that to every snap.

So the optimal approach would be to only draw one piece of the pie and pattern it at the end:

create a variable "n" with the number of snaps you want.

the first main shape could be made with a revolve. (symmetric, revolve angle=360/n)
in this case (with no revolve) you could intersect extrude a pie shape with 360/n angle.

add the snap hook. fillet and finish it as you wish.

then circular pattern the whole part using n as the instance count.

Your sketch is not the most optimal for this tooth profile (it is made of a large number of obviously non-tangent line segments, the root fillet is not tangent to the tooth, etc)

If you want to try to make a "wavy" tooth gear you could piggyback on top of the excellent Spur gear custom feature… https://cad.onshape.com/documents/5742c8cde4b06c68b362d748/v/1db29081376c095cf10e2a3d/e/c72760543a0d4412e72f6d38

Make a dummy gear the appropriate size - I think yours is 23 teeth, module=1mm, (i.e. PCD=23mm) Give it some arbitrary depth like 5mm. Make another Spur gear offset from this: you could transform copy, make it from scratch, or a 1000 other ways it is not so important… Now Loft between two faces of these dummy parts with Normal to profile as the boundary conditions for both profiles. Use Connections and pick two appropriate vertices on the teeth you want connected. You only have to do this for a single pair, the loft will take care of itself.

Check it out here: https://cad.onshape.com/documents/40a250b23fd3c4edabf65acf/w/dc15b086669c71b347a59ee4/e/b07d08c99dfa0e176d7ccdce