I have spent a few years now playing with metal gears that are additively manufactured so I decided it was time to show something neat. Below are 3 different gears that are printed with different methods and/or finished differently. Two are 20dp and the other I forgot but just wanted to show something after polish. Material is 17-4ph on all 3 gears. The two binder jet gears are solid but the extrusion based gear is 15% dense from 5mm below gear dedendum to 5mm outside of hex.
Binder Jet and BMD printed gears. The third is a not a 20dp gear but shows a Binder Jet gear after several hours in a polishing system.
Top down view to show surface finish differences between extrusion based and Binder Jetting. Both gears are direct from furnace.
Closer look at a project with @zsm150 for a new rev of swerve. He can deep dive but allows azimuth rotation and power transfer to occur on the same axis.
Gear highlighted in blue.
General tolerance on Binder Jet one-off parts I am seeing ~1% for the first print attempt. This is then tuned in to get much better for the final part. BMD will see 1-3% if you are running things correctly and rescale a few times. I am probably going to use this thread to continue to upload cool little parts as I continue to explore printing with robots. I do a lot of plastics too but those are boring, everyone does that. If you guys want to know more on the process, part design, etc just let me know.