Re: Gearbox Design Feedback
 

Actually superb can't cut the plates out since the max thickness for laser cuts is 1/8".

EDIT: On second thought, they might be able to since their site says they can cut up to 1/2" thick steel. Ill have to contact them on this.

Re: Gearbox Design Feedback
 

Yeah, water jetting or CNC milling.

Re: Gearbox Design Feedback
 

Question about filleting. How do you determine the largest end mill you can use in a fillet?

Re: Gearbox Design Feedback
 

Depends on what you're machining. For a 1/4" plate I would not go below a 3/16" end mill if I could avoid it, a 1/4" if at all possible due to its greater rigidity.
A fillet should be at least the radius of the end mill. So if you choose a 1/4" end mill, then you need at minimum a 1/8" fillet on corners. However, it's not good to go into a corner and move out of it so suddenly with an end mill, so it's better to go a bit larger (0.135"? not sure).

EDIT: End mills are referred to by diameter, and fillets by radius.