Yo-clone-oh Dogfighter

[atomic-carbon]

Thanks for the info i will have to give the esun CF a try, i found with tpu i had to pop it in the oven for a 1 hour to get reliable prints.

If you use prusaslicer there is a option for elephant foot compensation, which i have found pretty much eliminates elephant foot.

What fan settings to do you use for the esun CF ?, as normally i dont think you run the part fan.

[Dadio]

fan off unless its a tall narrow section like a two perimeter tube then 50-60% fan speed ,retractions just like PLA or ABS and speed just like PLA no need to slow it down like PETG or TPU .

[GoMachV]

I'm using Esun EPA- CF

I will have to try some as well. The NylonX and NylonG I use are expensive, so an alternative is always welcome.
Are you using a hardened nozzle or a ruby?

[Dadio]

I'm using a stainless steel nozzle , I had to bump the temperature up a bit but its working , I was using the nozzle that came with the Micro Swiss hot end as I thought it was stainless steel but its just coated brass and wore out completely in just under 1 kg of filament , it just wore the bottom of the nozzle right off and you could see the brass inside , had me foxed for a while as the prints went downhill and I thought it was a steel nozzle so I looked everywhere else for the problem before realising what it was .

[Dadio]

Bit of necro posting but this is the gear set commercially printed by Shapeways , the gear mesh looks and feels great , I need to just tweak the diff gear slightly as the pressure plates make very slight contact with the gear rather than just floating on the balls but we're talking only 0.1mm more clearance .
Next is road testing before I release them to the public for sale , this is the last piece of the puzzle as the rest is now all on Shapeways

[coxbros1]

Cant believe u know how to do that stuff!...HOW?

[Dadio]

Cant believe u know how to do that stuff!...HOW?

It's a secret so don't tell anyone but I don't really know how to do any of it no joke
I got the car back together and out for a run , all sounded very sweet but the battery dumped after about 1 minute before I can be confident selling the gears I need to put at least an hour's running on them then pull them out to inspect them , that's 12 old school packs so it should be enough to see how they are wearing .

[Dadio]

25 minutes running and still sweet

[Frankentruck]

Oh the horrible burden! I have to go run my RC car for 1 hour with back to back runs!

What materials are those gears printed in? Are you running them dry? For testing I presume you are because that would be the most harsh.

[Dadio]

They are professionally printed in PA12 Nylon, SLS printed (selective laser sintering) by Shapeways .
They are lubed with white lithium grease , I'm not that cruel , I'm up to 45 min now , got bored with the silver can and switched out for an Epic "EA motorsports " 27 turn heavily timed fixed timing motor and it's ripping along now , motor is just getting toastie after five min on 2s lipo , I should probably drop to 7.2 v NiMH but I'm having fun
When I changed out the motor there was no sign of wear yet in fact you could still see the layering in the contact area so it's looking good

[Dadio]

I actually ended up running 4 4000mah 2s lipo's through the gearbox , about an hour and ten minutes , the last half hour with a pretty pokey motor and I've just pulled the box apart .

After cleaning you can see no significant wear , the spur gear is kind of stained by the aluminium pinion and these prints do have a textured finish not polished smooth so the slightly mottled staining is not wear , in fact it's not even worn the texture flat so it's more promising really to see it.
Below is the motor used in the latter half hour of testing .

[Frankentruck]

I think phase 2 of testing should be driving the buggy for an hour, so there's load on the gears.

[Dadio]

Its has been driven so far for over an hour , mostly on road but with some short grass as well so it's been fully loaded not just bench tested , no real value to bench testing , my feeling is they are good to go but if the consensus is to go another hour of road testing then I guess I'll just have to suffer through it .

[Frankentruck]

While I do think you should suffer by driving and enjoying it more, I misunderstood your testing summary as only being no load bench running. My apologies for that, but not for wishing more operating time onto you. That seems like appropriate suffering as a result of your endeavors.

[coxbros1]

Oh the horrible burden! I have to go run my RC car for 1 hour with back to back runs!

....actually it is if you get caught!