Composite sprocket

A composite sprocket comprising:

• a skeleton having a connection interface and an outer portion having a rough tooth structure, wherein the connection interface and the rough tooth structure have a first tolerance;
• and
• an overlay formed on and over the outer portion of the skeleton and forming a high precision tooth structure over the rough tooth structure, the high precision tooth structure have a second tolerance and the overlay configured to cover an inner surface of a hub to form a high precision mating feature;
• the first tolerance is greater than about plus or minus 0.030 inches;
• the second tolerance is less than about plus or minus 0.010 inches.

A composite sprocket comprising:

• a skeleton having a hub and an outer portion having a rough tooth structure;
• and
• an overlay formed on and over the outer portion of the skeleton and comprised of a precision material and forming a high precision tooth structure over the rough tooth structure;
• the hub is configured with a mating feature to facilitate rotational movement of the sprocket about an axis
• the skeleton is comprised of iron and is formed by a rough casting without metal finishing;
• the precision material of the overlay is a castable urethane;
• the skeleton formed having a low precision with tolerances of plus or minus 0.060 inches;
• the overlay formed having the high precision with tolerances of plus or minus 0.015 inches;
• the skeleton has a tensile strength of about 65.5 to 172 Mega pascals (Mpa) tensile strength, yield;
• the overlay has a tensile strength less than about 6,600 psi;
• the tooth structure comprising 9 teeth;
• the overlay configured to cover an inner surface of the hub to form a high precision mating feature.