Gearhead iPhone 5/6 Dock, Spiral Bevel Gear 51T/17T, 3:1 Ratio

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This is an innovative, fully functional rotating spiral bevel gear iPhone dock. Yes, it's a mouthful, but this is the ultimate EngiNerdy desk accessory. As an engineer by trade, I'm naturally drawn to gears and mechanical systems. This dock was designed specifically for the OEM Apple lightning cord to route through the rotational shaft/base, preventing binding when the assembly rotates. Using GearTrax CAD software, I created a perfect spiral bevel gear mesh with a 3:1 reduction ratio. I printed this design in eSun white PLA on an Ultimaker 2 Extended with precise settings: 210C external temperature and 60C bed temperature. The print parameters were 25 mm/s for the first layer speed and 60 mm/s for the rest of the print, ensuring a smooth finish. A brim was added for adhesion of the gears, eliminating the need for supports during printing. To ensure optimal performance, the gears should be fully filled to prevent delamination under gear loading. The shaft is press-fit, requiring a rubber hammer and socket over the shaft to assemble it to the pinion. M4x20mm hex bolts were used to attach the dock to the 51-tooth gear, readily available at most hardware stores. If you have any questions or concerns, feel free to leave a comment. Have fun exploring this unique design!