Gears

From

Introduction

We need Gear Families that all work with each other. This includes popular construction toys. But we're also scaling stuff up to work with Big Iron, like 40mm and 100mm Frames. And rack and pinion.

Challenges

Compatibility with existing gear and sprocket families:

  • Meccano/Erector/Vex
  • LEGO Technic
  • Bicycle

Approaches

Laser Cutter

3D Printing

CNC mill/router

  • Sherline examples
  • Taig Mill examples
  • Bridgeport examples

Hybrid

Hybrid fabrication; RepRapping and then precise tidying of each layer with a milling/routing head is the most promising.

Hobbing

  • Timothy Edward's build of a Meccano Gear Making Machine, technically a gear hobber:

via http://edwards.web.users.btopenworld.com/meccano/modelgear.htm

Wire EDM

Main page: ElectrochemicalPrintedCircuitBoardHead#electric discharge machining
  • Forrest Higgs proposed this once.

Casting/Mouldmaking

CNC plasma cutting

2D cuts can be stacked, with through holes for bolts to provide alignment and compression, allowing for the construction of sturdy power transmission components for keyed shafts.

References