[AdamHeard]

For varied reduction single speed gearboxes, we've done something that I have poorly named in CAD as "AM based lasered gearbox plates".

It's a neat concept, we decide that regardless of gearing needs, we will ONLY use andymark toughbox gears. That means spurs with a .4 overall thickness, and pinions with a .6 overall thickness. Both already have machined nubs so they don't rub on the bearings.

Then, you can machine gearbox plates by whatever means (we like waterjet/laser as it's obviously fast and allows more flexible design).

Design the plates to be 1.125" apart (we usually bolt onto a 1" face with a .125" spacer.

For assembly, press bearings in, and you can use exclusively AM shafts if you desire. We machine our own to perfectly match our needs and eliminate spacers, but this is not necessary.

Doing this allows you to create custom gearboxes FAST and with minimal machining. We've shown you can get just about any reduction, from 1:1, to several hundred to one.

For my first custom geaarbox, I would go in this direction; utilize COTS gears and shafts. Machine only plates, and possibly standoffs. Spacers should not be necessary if you design it right (standoffs as well possibly)!

If you want the CAD for these to make the concept more clear, let me know.

Oh, last little tip, we also try to exclusively use 50T spurs. this allows us to use the aluminum gears AM sells. We cut weight off with our lathe and mill and get them down to .07 lbs each (versus .5 for the stock steel!).