It has to be taken in to account. Using oversized gear and pinion as electrodes does not solve the problem because it is impossible to cut the gear that is oversized in the same directions that plastic shrinks. 3D cad models have to be used for mold design and inspection. However such of model has low accuracy. DDS tool allows to create 3D CAD files of the theoretical gears.
Pressure angles on front and rear part of the pinion.
The gears almost always have two different pressure angles on the same tooth. The front working angle is usually about 10 and rear angle is 30 degrees. Different pressure angles are not a very good solution for the drive that has to rotate in both directions. Computer models with equal pressure angles have been designed on DDS software. TCA and contact pattern developing.