Cable-pulling Servo Horn (25 tooth)
by wmhilton, published
This is a customizable version of my earlier String Puller Servo Horn with one big giant feature - the servo splines are built in! (See note at the end.)
The downside to that of course is, you need a high resolution 3D printer to print it. (I have access to a Stratasys Dimension Elite with 0.178mm resolution at Drexel University.) The other downside is since the dimensions of the splines are an educated guess (made by staring at the stupid horns with calipers for many hours) they may or may not be a good match.
Shout-out to Jhack for inspiring me to make it Customizer-friendly!
Regarding the Splines:
So now that I've printed the part, I can say that the teeth don't really turn out. Probably because the printer resolution just really isn't there even on a Stratasys Dimension Elite. However, they worked "well enough" just by forcing them onto the metal servo spline. I would describe it as a kind of a press fit, except you can pop it off with a flat head screwdriver.
My recommendation would be... try it! It worked well enough for me that I plan to continue manufacturing my horns this way.