Many thanks. I need to pick up my package today from Postnet so hopefully tonight I will have the pop cycle in my hands. I have cut the cord you posted in a 1/3 of its length and will print it in PLA just to see if it fits the gap and spacing of the "gear tooth".
If it fits I was thinking that instead I should make a mold and then just cast more. I see the member on Thingiverse mentioned Smooth-Cast 65D.
Never cast anything in my life so lets see how this goes. I also see Pratley has a product called FroggyEggs. Might try that as well. Think in the long run its easier to mold and cast than to print 50 odd zip cords.