How do I create gears for the MG996 FPV Servo.

I am planning on using the 6 toothed attachment for the servo but I need a gear design that will be able to be rotated. I will need to put this in the S500 Dev kit at the bottom of the battery mount. This needs to be 3d printed btw so take account of making sure I can actually slide rods through it. The rod is 0.201 diameter in inches. I want it to have 4 gears connected by rods and 1 being directly connected to a gear or the servo.
Outside claw size is 17 by 5 in a rectangle.

Sorry if this is a lot

1 Answer

Understand the Gear Specifications:
- Disassemble the MG996R servo carefully to access the internal gears.
- Measure the gears using calipers to determine:
- Number of teeth.
- Module (or diametral pitch) of the gears.
- Pitch diameter.
- Gear thickness.
- Shaft diameter (for the center hole).
- Take note of the gear type (e.g., spur gears, helical gears).

Use CAD Software to Design the Gears:
- Use CAD software like SolidWorks, Fusion 360, or FreeCAD to design the gears.
- Most CAD software has built-in gear generators:
- In SolidWorks, use the Toolbox or GearTrax plugin.
- In Fusion 360, use the Spur Gear or Helical Gear generator in the Design workspace.
- Input the measured parameters (number of teeth, module, etc.) to generate the gear profile.

Export the Gear Design:
- Once the gear is designed, export it as an STL or DXF file for 3D printing or CNC machining.

Choose the Manufacturing Method:
- 3D Printing:
- Use a durable material like Nylon, PETG, or Carbon Fiber Reinforced PLA.
- Print the gears with high precision and minimal layer lines for smooth operation.
- CNC Machining:
- Use materials like Aluminum or Brass for metal gears.
- CNC machining provides high strength and durability for high-torque applications.

Post-Processing:
- For 3D-printed gears:
- Sand the gears lightly to remove any rough edges.
- Lubricate the gears with silicone grease to reduce friction and wear.
- For CNC-machined gears:
- Deburr the edges and ensure smooth operation.

Assemble and Test:
- Reassemble the servo with the new gears.
- Test the servo to ensure smooth operation and proper torque transmission.

Tips for Success:
- Material Selection: Choose materials that can withstand the torque and stress of the MG996R servo.
- Precision: Ensure the gears are designed and manufactured with high precision to avoid misalignment or jamming.
- Backup Gears: Always keep a set of spare gears in case of failure.