In December 2016, [Bruno M.] was lucky enough to score a 70+ year old Logan 825 lathe for free from Craigslist. But as you might expect for a piece of machinery older than 95% of the people reading this page, it wasn’t in the best of condition. He’s made plenty of progress so far, and recently started tackling some broken gears in the machine’s transmission. There’s only one problem: the broken gears have a retail price of about $80 USD each. Ouch.
On his blog, [Bruno] documents his attempts at replacing these expensive gears with 3D printed versions, which so far looks very promising. He notes that usually 3D printed gears wouldn’t survive in this sort of application, but the gears in question are actually in a relatively low-stress portion of the transmission. He does mention that he’s still considering repairing the broken gears by filling the gaps left by the missing teeth and filing new ones in, but the 3D printed gears should at least buy him some time.
As it turns out, there’s a plugin available for Fusion 360 that helpfully does all the work of creating gears for you. You just need to enter in basic details like the number of teeth, diametral pitch, pressure angle, thickness, etc. He loaded up the generated STL in Cura, and ran off a test gear on his delta printer.
Of course, it didn’t work. Desktop 3D printing is still a finicky endeavour, and [Bruno] found with a pair of digital calipers that the printed gear was about 10% larger than the desired dimensions. It would have been interesting to find out if the issue was something in the printer (such as over-extrusion) or in the Fusion 360 plugin. In any event, a quick tweak to the slicer scale factor was all it took to get a workable gear printed on the third try.
This isn’t the first time we’ve seen 3D printed gears stand in for more suitable replacement parts, nor the first time we’ve seen them in situations that would appear beyond their capability. As 3D printer hardware and software improves, it seems fewer and fewer of the old caveats apply.