Problems with output resolution

[ftkalcevic]

I'm trying to generate some timing pulleys to export as DXF.

The pulley is HTD3m, 15 tooth, units mm.

If I use the default "gear point dist" setting of 0.1, I get an output that isn't precise enough, as shown in the first attachment.

If I set the "gear point dist" to 0.01, I get a very uneven result, which cripples alibre design, as shown in the second attachment.

[Edit: Note the first image is the comped version, but the non-comped is the same]