Questions
What tools will need to be used to accurately measure the geometry of the gear?
What material would be best suited for this application?
Challenges
The gear contained very complex geometry and needed to be able to withstand wear and tear over time.
Solution
Utilizing an optical comparator, calipers, and a radius gage set, I was able to measure the gear geometries with accuracy and add dimensions to a hand sketch.
Afterwards, I modeled the part in SolidWorks and exported an STL file for printing.
Engineering-grade ABS plastic was chosen for this part for its high impact strength, durability, and resistance to heat, chemicals, and wear.
The replacement gear was printed on a Stratasys Fortus 360mc FDM Printer.
Before and After
The new gear restored the chair to its original function.
This project really expanded my reverse-engineering skillset—it was quite the challenge!