Hybrid manufacturing Nylon gear

An example hybrid manufacturing project I undertook for a competition. I used a single machine (Snapmaker A150) and a single piece of software (Autodesk Fusion 360) to 3D print and CNC router a compound Nylon (Taulman Alloy 910) spur gear. Hybrid is technically both operations in a single step but this is close enough. I took my designed CAD model for the gear, and built up a manufacturing model of the stock piece to be printed. I included fixing holes, a flat edge for referencing against the straight edge, and flat edges for zeroing reference. The straight edge itself was a challenge to produce since the machine was not designed with any sort of reference edge built in as it is a basic CNC router. The CNC surface is also removed when swapping to the 3D printing or laser work surfaces. So the edge has to reference accurately against the machine each time it is installed (this was a separate hybrid manufacturing project). The final part came out nicely, except there was slight delamination on some of the teeth. Higher temperature print settings and a compression router bit would solve this. I have included the fusion file with all parts of the project, part design, additive manufacturing (right click the additive setup and select generate to load the toolpaths) and machining. I find it quite remarkable that this can be done with this free software.

Files (10)

License: CC - Attribution - Non-Commercial Learn more
mechanical gear hybrid manufacturing mechanical-engineering solid-modeling spur-gear gear-box design-3d cnc-router additive-manufacturing cnc-fixture cnc-cutting hybrid-manufacturing compound-gear polymer