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Building and Testing a 3D Printed Planetary Gearbox: A Comprehensive Guide

Introduction

In this detailed guide, we will walk you through the process of building a 3D printed planetary gearbox from scratch. From designing the gearbox in Fusion 360 to testing its functionality, we cover every step along the way. Whether you are a novice or an experienced maker, this comprehensive tutorial will provide you with valuable insights into creating and testing your own planetary gearbox.

Step 1: 3D Printing the Necessary Parts

To commence the project, start by 3D printing all the essential parts required for the planetary gearbox. You can find the free STL files in the description of the video. When printing gears, it is recommended to use a raft to prevent an elephant foot effect, especially crucial for the smooth functioning of a planetary gearbox.

Step 2: Assembling the Gearbox

1. Sun Gear Assembly:

   • Insert M3 nuts into the sun gear, ensuring the holes are centered.
   • Securely screw a 3mm set screw through the holes, aligning the double helical gears correctly.

2. Ring Gear and Planets:

   • Assemble the ring gear and ensure it holds the planets and sun gear securely in place.
   • Verify that the gears spin freely before proceeding.

3. Motor Installation:

   • Mount the motor using the appropriate holder, such as one designed for a 775 motor or a NEMA 17 stepper motor.
   • Connect the motor to the adapter using 4mm bolts and insert the motor shaft into the sun gear's center hole.

Step 3: Testing and Troubleshooting

After assembly, proceed with testing the gearbox by powering the motor. Ensure that the gears run smoothly and without any obstructions. Make necessary adjustments to fix any issues encountered during the testing phase for optimal performance.

Gear Design in Fusion 360

1. Gear Generator Plugin:

   • Utilize the helical gear generator plugin in Fusion 360 for designing precise gears with specific parameters.

2. Designing Gears:

   • Begin by creating the ring gear, followed by the sun gear and planetary gears.
   • Utilize pitch diameters and the mirroring technique to generate double helical gears accurately.

3. Assembling the Gear System:

   • Position the gears correctly using calculations based on pitch diameters to ensure proper alignment.
   • Implement circular patterning for multiple planet gears to achieve the desired gear system.

Final Touches and 3D Printing Considerations

After designing the gearbox model, pay attention to the tolerances required for 3D printing. Adjust the gear teeth lengths accordingly to ensure smooth assembly and rotation of the gears. Experiment with different tolerance settings based on your 3D printer specifications for optimal results.

Conclusion

Building a 3D printed planetary gearbox entails a meticulous process of design, printing, assembly, and testing. By following the steps outlined in this guide, you can create your own functional gearbox for various applications. Experiment with different gear configurations and motor setups to customize your gearbox according to specific project requirements. Embrace the iterative nature of 3D printing and gear design to enhance your skills and create innovative mechanical solutions.

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