Inspired by the all-famous heart gears I decided to take the design one step further. The principle is the same but I've expanded it from 8 gears to 32.
I thought the iconic companion cube was a great shape to cut out of the gears and I wasn't wrong, it looks great and works really well!
I printed it all in ABS, it was a monster print with 20% fill it took my two printers 4 days to complete. The way I printed it was on one printer I printed all of the large gears in two batches of 6, whilst the other was printing all of the small gears in two batches of 10, then the printer which printed the small gears finished first and in time to print the 32 pins and the big core.
PDF of all 6 third angle orthographic projections included for help in assembly.
Only the Big Core needs some support to form the pin holes.
I did nice thick walls (6 layers) and slowed the print to 3000mm/min and ran cooling fans at 50% from layer 7 (second proper layer after raft).
See description for more printing advice.
Designed in Inventor
The process is simple enough.
-Create the core shape
-Create bevel gears using design accelerator, number of teeth must be divisible by number of mating faces and gears must be large enough to incorporate cut object.
-Duplicate design accelerator components
-Edit duplicates; loft front face to central point (making large cone shaped gears)
-Create multiple duplicates of edited components (each gear is different)
-Assemble all of the gears with the central core making sure mesh planes are aligned
-Create object shape
-Place shape in gear assembly in correct position
-In turn edit each gear in Assembly view copying the object surface then sculpting from each gear.
-At some point you need to create the pin holes. If you're competent in Inventor this should be trivial.