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I just attempt to create a 3D model of the gear using a blender tutorial and a calculator. It would be $5 for plastic (nylon) and $15 for steel. I haven't been able to shape the shaft correctly just yet though, but it gives a reasonable idea about pricing.
There is also a bigger gear in the unit that has the same problem but to a lesser degree (it's on the other side of the same axis). That too looks a little worn out and has a minor crack. It's much bigger though. I'm going to see if I can get the small one working first using the 3D model.
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