Hi all, we’ve been using some laser-cut plywood cogs in a project at our Escape Game. They have worked since october, but are now starting to break, and the upkeep is proving difficult.
We’re wondering how feasible it would be to either cast these cogs in a metal, or cut them from metal, and if either of these options would be achievable at the makerspace. The cogs are 12mm thick, and vary in diameter from around 20cm to 7cm. For ease of use we’d like them to be the same shape and size. I have the inkscape files if that helps.
I’d need a bit of guidance, maybe from a metaltech, as I’m inexperienced with metalwork, but once I’m pointed in the right direction and things seem safe I’d be happy to work on this.
So, as a general rule, yes, we theoretically have the facilities to cut gears, but this is all untested as we are still in the process of commissioning the horizontal mill.
We have a selection of gear-forming cutters, but we never tried them out yet, so no guarantees.
That said the project is extremely interesting, so if you happen to be in the space Friday or Saturday evening, definitely come in the metal area and chat with me or @VintageSteel, who knows, we may be able to get something in place to help you.
I’d make sure you have geometry of the gears correct. It will make a huge difference to longevity. This guy makes a lot of things with wooden gears without any issues, so I’m surprised to hear they’d wear out in an escape game so quickly
For something like an escape game, the tolerances you’d get on the CNC might be enough and you could cut them from aluminium. When you consider the price of stock, the number of failures you might get, and the number of tools you might break it could be cheaper to look at an online service like PCB way. It would be a lot less fun though
This is extremely relevant to my interests and aligned with things I want to do for my projects, which unfortunately I haven’t had time to dedicate to yet.
I have some limited experience cutting brass and steel gears using the “traditional” method, with gear cutters and a dividing head on the mill, in another makerspace.
I’d love to do that at SLMS, and our mill should be able to do it, we’d just need a dividing head.
Depending on what your needs are, though, like others said, you may get away with simpler methods…
Do you have specs for the gears you have now? Specifically, teeth shape and size/module? Are these relevant to your practical needs? Or pretty much “any gear will do”?
Have you thought about just a metal band on wood gears to make them harder wearing?
Delrin as a machining material or 3D printing are good alternatives.
You may find https://geargenerator.com/ of help. I have used it several times for laser cut gears (clock) and for generating 3-D profiles for gears with specific ratios and sizes. Not sure exactly what your application is but 12mm birch ply and a coarse pitch would surely last?? Just a bit tedious to cut on the fretsaw/bandsaw??
