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Would you know what type of approaches and machinery is needed for relatively loose tolerance / low load helical gears? If going the CNC route, do I need full 5 axis and specialized end mills?

Even with regular involute straight gears, there's a bunch of ways one could manufacture one, and I'm out of my depth here.



The industrial strength version: https://m.youtube.com/watch?v=EefFxEGVbWo

I made sprockets with an endmill and a simple macro on a C-axis lathe. Worked just fine since the tolerance on those is very forgiving.

In principle you could make a helical gear as a multi-start thread. I'll have to test it once I have the machine free an afternoon.




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