After the final CAD assembly model was complete, we began manufacturing the individual components. All linkages, housing pieces, the Geneva wheel, and the upper platform were laser cut from acrylic or wood. A motor support, two Bevel Gears, two Spur Gears, shaft and link couplings, the Geneva crank and Geneva mechanism base, structure supports, and a “blade” were all 3D printed from PLA plastic. 3D printing the gears was initially a worry, so they were printed at a finer resolution. They ended up meshing together nicely and worked well for our design. Additionally, we cut our main shafts from a ¼” diameter steel rod and connected them to our links with metal shaft couplers and collars. Several 5x11x4 mm ball bearings were used between rotating components to alleviate friction and to allow for smooth motion. The housing pieces were super-glued together with 3D printed “L-supports”, and the servo motor mount and Geneva mechanism base were super-glued to the inside of the housing. The shaft couplings were bolted to linkages, while all bearing connections were friction fit together.
