These files are the Fusion 360 source files of this project.

This servo/gear reduction uses mostly 3D-printed parts. The servo uses a 775 36V 9000rpm brushed DC-motor wich is driven by a BTS7960B motor driver wich is controlled by an arduino mega 2560. The stall torque of the servo is about 55kg/cm wich is about 5.39 Nm. the peak current is about 18 amps when using a 6s LIPO battery (about 22-24V). the reduction ratio is 1:30. I originally wanted to use some 20mm ball bearings for the outputshaft but they didn't arrive in time so I ended up using two 20mm holes and a lot of lubrication. For the intend of filming the internals of the servo for possible faillures, I printed some collored gears and lasercut a 5 mm acrylic lid. Unfortunatly I didn't get to film any awsome footage of gears exploding because they were far to strong ;-). Even at a peak torque of 54kg/cm they didn't show the slightest form of flexing or cracks. The two middle gears (blue and red one) use a stainless steel shaft of 6mm diameter. The holes of the gears are designed at 6.2mm diameter so they would fit nicely around the 6mm shaft but some additional filing/sanding might be required. The same might has to be done for the 20mm shaft holes.

I uploaded the dxf of the lid so people with a laser cutter can cut the lid out of transparant acrylic.

Video can be found here:https://www.youtube.com/watch?v=8sq4pHdSXYM

More info can be found here:https://hackaday.io/project/162855-3d-printable-high-torque-servogear-reduction

Components used:

1 × 775 Motor DC 12V-36V 3500-9000RPM Motor Large Torque High Power Motorlink:https://www.banggood.com/775-Gear-Motor-DC-12V-36V-3500-9000RPM-Motor-Large-Torque-High-power-Motor-p-1091058.html?rmmds=search&cur_warehouse=CN

1 × Arduino nano V3link:https://www.banggood.com/Geekcreit-ATmega328P-Nano-V3-Module-Improved-Version-With-USB-Cable-Development-Board-For-Arduino-p-933647.html?p=E01411629100201406T1&custlinkid=255135

1 × L298N motor driverlink:https://www.banggood.com/Wholesale-Dual-H-Bridge-DC-Stepper-Motor-Drive-Controller-Board-Module-Arduino-L298N-p-42826.html?p=E01411629100201406T1&custlinkid=255131

1 × Heat shrinkslink:https://www.banggood.com/328pcs-Heat-Shrink-Tubing-Insulation-Electrical-Shrinkable-Tube-Sleeve-Cable-21-p-1362019.html?p=E01411629100201406T1&custlinkid=669227

2 × stainless steel shaftdimensions: 6mm diameter, 70mm lenght

2 × M5 bolt and nutdimension: 40mm lenght

1 × 20mm steel tubedimension: 125mm lenght

2 × screws 15mm lenghtdimension: 4.5mm diameter, 15mm lenght

5 × screws 35mm lenghtdimension: 4.5mm diameter, 35mm lenght

Recommended Tools:

3D-printer:https://www.banggood.com/Creality-3D-Ender-3-Pro-V-slot-Prusa-I3-DIY-3D-Printer-Kit-p-1346320.html?p=E01411629100201406T1&custlinkid=677427