Bevel Gear Differential with 5/8" Axles

thingiverse

Here is the differential assembly featuring four bevel gears. For successful construction, print two sets of all components except DiffInnerAxle5_8.stl. Using a 0.3mm layer height with 15% infill was standard practice for this project. The bevel gears showcased an 18-tooth design, 1.5" pitch diameter, and respective heights of 1" and 3/4" for the tall and short gears. For each printed part, a standard process included filing bore holes slightly to allow easy passage of axles and promote smooth rotation. Careful attention should also be paid to keys and keyways for facilitating press fits onto their respective bevel gear counterparts. A coat of silicone spray or another suitable plastic lubricant should be applied generously across the assembly's components. To securely connect both housings, PC case screws can serve as a viable option, with caution taken regarding their precise specifications. Upon completing this integration, apply a few gentle rotations to each axle until a satisfying ease of spinning is achieved throughout. This controlled break-in process plays a critical role in optimizing differential performance.