This guy is amazing - https://www.3dhubs.com/service/ara3d

You might find someone in your area on that site also.

Shapeways is a good 3D print service, lots of material options. Add a few Pinsiders here that can draw up.

Do a search of pinball at Shapeways

Does that gear drive a chain? It looks like it from the shape of the teeth.

That was likely made from Nylon, which is a lot tougher than ABS and PLA (what most printers use for material), so I would pick Nylon or a metal for a suitable replacement.

Recreating that in CAD wouldn't be too tough. I would go with Alumide from Shapeways. http://www.shapeways.com/materials/metallic-plastic?li=nav Either that or steel. More expensive, but more durable.

I would tend to stay away from the alumide as it is basically nylon with aluminium flakes and looks nice but weakens the bond for the nylon. I would just go for the nylon material personally as quite robust. Somerimes it is good to have a weak link designed in. Having a metal gear may transfer the weak link to the motor or bracket. Also once designed you could strengthen up in places - check out the Bally ball launch part - standard and modded (strengthened).

I could help if you cover postage but would need a sample to design from

I'd request an SLS printed part made from nylon.

Try Pinballlife, I have had them make several 3D printed parts and it's not too expensive.

http://www.pinballlife.com/index.php?p=product&id=3421

SLS and extrusion methods are two very different ways to print. SLS printers cost 10's or 100's of thousands of dollars and extrusions styles are a lot cheaper. Extrusion melts layers of material on top of other layers. SLS uses a laser to sinter (fuse) powders of that material together. The biggest differences are the standard surface finishes, SLS being much better, and that extrusion prints are very weak in the direction of the layers.

Shapeways does SLS, the other linked store looks like an extrusion style makerbot printer. Pinball Life and Mezel Mods do extrusion based printing as well, which is most of the reason why they don't do anything for me as far as wanting them.

Send me a PM, Might be able to cad that up for you considerably cheaper. Even do an ABS sample to make sure it works before sending to shapeways.

I don't have a great CAD program, but here's what I came up with. Made some rather generous fillets to help with stress relief in case you go with a filament printed part. Also went a LOT thicker around the drive boss. I'll do an ABS sample tomorrow and get it mailed out as I'm sure there will be some tweaks to dimensions.

gear (resized).jpg