Forrest's success at milling spur gears with Tommelise 2.0 got me wondering how well RepRap can make them with Fused Filament Fabrication. An obvious test case are the two gears on Ian Adkins' alternative extruder design. These are laser cut, but look just about achievable with FFF. I couldn't find a picture of Ian's, these are a similar design by Vik Olliver.
Here is how they came out :-
The infill does not meet the toothed edge very well but they seem very strong never the less. They mesh well even though the involute profile seems a bit rounded off.
In an attempt to get the infill to work better I tried running my machine with 0.3mm filament, 0.24mm layers. I didn't make the nozzle hole smaller, I just changed one number in my software so the filament is being stretched finer. The result was interesting :-
The infill fills the teeth and is also very flat. The hole for the motor shaft has come out smaller and the teeth are a bit asymmetrical. They lean clockwise, the direction the outline is laid down in. I think this is because I am extruding 0.3mm filament through a 0.5mm hole so the point it exits from can move about but 0.2mm. I expect using a 0.3mm hole will solve that.
I also had a go at making a smaller version of my screw top pot with 0.3mm filament. I used the same g-code, I just scaled all the coordinates by 0.3/0.5.
It came out well and the thread still works.
With the finer filament it takes about 3 times longer to make anything so I upped the speed from 16mm/s to 32mm/s. That had an unfortunate side effect: The wall of the pot is quite thin so after the outline and inner wall have been extruded, the infill is a very narrow zig-zag. That makes it a high frequency movement. Speeding it up made it more like an audio vibration which seems to resonate the frame of my machine, shaking anything loose off the desk.
HydraRaptor growling from Nop Head on Vimeo.