This servo/gear reduction was assembled with almost all 3D-printed parts. Apart from a brushed 36 V DC-motor, a stainless steel shaft, and screws for holding the servo together, the only other non-printed part is the BTS7960B motor driver.
Some interesting stats about the plastic servo – its stall torque is about 55 kg/cm, reaching a peak current draw of 18 A when using a 6s LiPo battery outputting 22-24 V. The shaft rotates using two 20 mm holes and lubrication. (Ball bearings were originally in the design, but they didn’t arrive on time for the assembly.)
The holes of the gears are 6.2 mm in diameter in order to fit around the shaft, although some care is taken to sand or fill the opening depending on the quality of the 3D print.
This isn’t [Brian Brocken]’s only attempt at 3D-printing gears. He’s also built severalcrawling robots, a turntable, and a wind up car made entirely from acrylic. The .stl files for the project are all available online for anyone looking to make their own 3D-printed servo gears.
Interfacing a shaft to a 3D printed gear doesn’t have to be tricky. [Tlalexander] demonstrated a solution that uses one half of a spider coupling (or jaw coupling) to create an effective modular attachment. The picture above (and this older link) shows everything you need to know: the bottom of the coupling is mounted to the shaft, and a corresponding opening is modeled into the the 3D printed part. Slide the two together, and the result is a far sturdier solution than trying to mate a 3D printed gear directly to a motor shaft with a friction fit or a screw. This solution isn’t necessarily limited to attaching gears either, any suitable 3D printed part could be interfaced to a shaft in this way.
These couplings are readily available, and fortunately for hobbyists, come in sizes specifically designed for common stepper motors like NEMA 17 and NEMA 23. Ironically, these couplings are often used when building custom 3D printers for those same reasons. With this method interfacing anything at all to a motor shaft becomes mostly a matter of modeling a matching hole out of the part to be 3D printed. One coupling even provides two such attachments, since only one of the two sides is used.
Even a relatively low-end desktop 3D printer will have no problems running off custom enclosures or parts for your latest project, and for many, that’s more than worth the cost of admission. But if you’re willing to put in the time and effort to become proficient with necessary CAD tools, even a basic 3D printer is capable of producing complex gadgets and mechanisms which would be extremely time consuming or difficult to produce with traditional manufacturing techniques.
Printable bearing cross-section
Once you find yourself at this stage of your 3D printing career, there’s something of a fork in the road. The most common path is to design parts which are printed and then assembled with glue or standard fasteners. This is certainly the easiest way forward, and lets you use printed parts in a way that’s very familiar. It can also be advantageous if you’re looking to meld your own printed parts with existing hardware.
The other option is to fully embrace the unique capabilities of 3D printing. Forget about nuts and bolts, and instead design assemblies which snap-fit together. Start using more organic shapes and curves. Understand that objects are no longer limited to simple solids, and can have their own complex internal geometries. Does a hinge really need to be two separate pieces linked with a pin, or could you achieve the desired action by capturing one printed part inside of another?
If you’re willing to take this path less traveled, you may one day find yourself creating designs such as this fully 3D printed turntable by Brian Brocken. Intended for photographing or 3D scanning small objects without breaking the bank, the design doesn’t use ball bearings, screws, or even glue. Every single component is printed and fits together with either friction or integrated locking features. This is a functional device that can be printed and put to use anywhere, at any time. You could print one of these on the International Space Station and not have to wait on an order from McMaster-Carr to finish it.
With such a clever design, I couldn’t help but take a closer look at how it works, how it prints, and perhaps even some ways it could be adapted or refined going forward.
What do you do if you want a robot with great mobility? Walking is hard, and wheels are good enough, especially if you use the ‘wheels within wheels’ Mecanum setup. But you need torque, too. That’s what makes this entry into the Hackaday Prize so fantastic. It’s a Mecanum wheel of sorts, with an integrated gear set that produces a phenomenal amount of torque using a small, cheap stepper motor.
The wheel itself if 3D printed and fully parametric, using nylon weed wacker filament for the treads. This allows the wheel to scoot back and forth like a Mecanum wheel, or at the very least like one of those hyper mobile wheeled robots you see from time to time. It goes backwards, forwards, and side to side, and also has a zero turn radius.
A 3D printed Mecanum wheel is great, but how on earth do you drive it? That problem is solved with this hybrid planetary/strain-wave 3D-printed gear set. [Daren] has created a very compact ‘single’ stage gear set that fits right on top of a stepper motor. It’s thin, flat, and has a gear reduction of about 66:1. That’s a lot of torque in a very small package. Both of these projects are combined, and together they represent a freaky wheel with a lot of torque.
Even though [Daren] doesn’t have a robot in mind for this build, these are most certainly the building blocks of a fantastic robot, and a great entry in the Hackaday Prize.
The king of machine tools is the lathe, and if the king has a heart, it’s probably the leadscrew. That’s the bit that allows threading operations, arguably the most important job a lathe can tackle. It’s a simple concept, really – the leadscrew is mechanically linked through gears to the spindle so that the cutting tool moves along the long axis of the workpiece as it rotates, allowing it to cut threads of the desired pitch.
But what’s simple in concept can be complicated in reality. As [Clough42] points out, most lathes couple the lead screw to the spindle drive through a complex series of gears that need to be swapped in and out to accommodate different thread pitches, and makes going from imperial to metric a whole ball of wax by itself. So he set about building an electronic leadscrew for his lathe. The idea is to forgo the gear train and drive the leadscrew directly with a high-quality stepper motor. That sounds easy enough, but bear in mind that the translation of the tool needs to be perfectly synchronized with the rotation of the spindle to make threading possible. That will be accomplished with an industrial-grade quadrature encoder coupled to the spindle, which will tell software running on a TI LaunchPad how fast to turn the stepper – and in which direction, to control thread handedness. The video below has some great detail on real-time operating systems on microcontrollers as well as tests on all the hardware to be used.
If you don’t know what a print processor is, don’t feel bad. There’s precious few people out there still running home darkrooms, and the equipment used for DIY film development is about as niche as it gets today. For those looking to put together their own darkroom in 2019, buying second hand hardware and figuring out how to fix it on your own is the name of the game, as [Austin Robert Hermann] found out when he recently purchased a Durst Printo Print Processor on eBay.
The auction said the hardware was in working order, but despite the fact that nobody would ever lie on the Internet, it ended up being in quite poor condition. Many of the gears in the machine were broken, and some were simply missing. The company no longer supports these 1990’s era machines, and the replacement parts available online were predictably expensive. [Austin] determined his best course of action was to try his hand at modeling the necessary gears and having them 3D printed; two things he had no previous experience with.
Luckily for [Austin], many of the gears in the Printo appeared to be identical. That meant he had several intact examples to base his 3D models on, and with some educated guesses, was able to determine what the missing gears would have looked like. Coming from an animation background, he ended up using Cinema 4D to model his replacement parts; which certainly wouldn’t have been our first choice, but there’s something to be said for using what you’re comfortable with. Software selection not withstanding, he was able to produce some valid STLs which he had printed locally in PLA using an online service.
Being able to coast on a bicycle is a feature that is often taken for granted. The use of a freewheel was an improvement made early in the bicycle’s history, for obvious reasons. This also unlocked the ability to build bikes with multiple gears, allowing higher speeds to be easily reached. On a unicycle, however, there’s no chain and the pedals are permanently fixed to the wheel’s axle, meaning that there is (usually) no freewheel and no gearing. [johnybondo] wanted to get some more speed out of his unicycle, though, and realized he could do this with his own homemade internal geared hub for his unicycle.
The internal hub gear was machined and welded by hand as a one-off prototype. There are commercial offerings, but at $1700 it’s almost best to fund your own machine shop. It uses a planet gearset which is more compact than a standard gear, allowing it to fit in the axle. Once all the machining was done, it was time to assemble all of the gears into the hub, lace it to the wheel with spokes, and start pedaling away. Since it was so successful, he plans to build another and lace it to a larger wheel which will allow him to reach even higher speeds. If this isn’t fast enough for you, personally, there are other options available for ludicrous speed.
Now, this gear is still “fixed” in the sense that it’s a permanent gear ratio for his unicycle and it doesn’t allow him to shift gears or coast. There’s no freewheel mechanism so the unicycle can still be pedaled forward and backwards like a traditional unicycle. The advantage of this setup is that the wheel spins 1.5 times for every one revolution of the pedals, allowing him to more easily reach higher speeds.
