A method of making a worm gear is provided. The method comprises forming a gear hub from a powdered metal material. Thereafter an outer surface of the gear hub is sealed.

Rotors formed by an additive manufacturing process are presented. In one example, a method of making a rotor is presented including defining a printing order for the application of a first material, and creating a plurality of lobes arranged helically about a central opening or a shaft by adding a first material in the printing order, wherein each of the plurality of lobes defines an outer surface.

Rotors formed by an additive manufacturing process are presented. In one example, a method of making a rotor is presented including defining a printing order for the application of a first material, and creating a plurality of lobes arranged helically about a central opening or a shaft by adding a first material in the printing order, wherein each of the plurality of lobes defines an outer surface.

A method for manufacturing a sintered gear comprising the steps of: preparing a cylindrical green compact; gear-cutting the green compact with a hob; and sintering the gear-hobbed green compact, wherein the hob is such that a ratio of a number of cutting edges thereof per round to a number of starts thereof exceeds 8.

A method for manufacturing a sintered gear comprising the steps of: preparing a cylindrical green compact; gear-cutting the green compact with a hob; and sintering the gear-hobbed green compact, wherein the hob is such that a ratio of a number of cutting edges thereof per round to a number of starts thereof exceeds 8.

A gear forming tool includes an outer sleeve having an outer sleeve aperture and an inner sleeve having an inner sleeve aperture in fluid communication with the outer sleeve aperture, a tool holder disposed within the outer sleeve, and a 3D printed gear cutting tool with a plurality of tool cutting edges and a plurality of capillaries attached to the tool holder. The tool holder has a plurality of fluid channels configured to be in fluid communication with the inner sleeve aperture and the plurality of capillaries of the 3D printed gear cutting tool such that cutting fluid flows through the outer sleeve, the inner sleeve, the plurality of fluid channels of the tool holder, and the plurality of capillaries to the plurality of tool cutting edges.

Methods for the fabrication of metal strain wave gear flexsplines using a specialized metal additive manufacturing technique are provided. The method allows the entire flexspline to be metal printed, including all the components: the output surface with mating features, the thin wall of the cup, and the teeth integral to the flexspline. The flexspline may be used directly upon removal from the building tray.

Methods for the fabrication of metal strain wave gear flexsplines using a specialized metal additive manufacturing technique are provided. The method allows the entire flexspline to be metal printed, including all the components: the output surface with mating features, the thin wall of the cup, and the teeth integral to the flexspline. The flexspline may be used directly upon removal from the building tray.

Methods for the fabrication of metal strain wave gear flexsplines using a specialized metal additive manufacturing technique are provided. The method allows the entire flexspline to be metal printed, including all the components: the output surface with mating features, the thin wall of the cup, and the teeth integral to the flexspline. The flexspline may be used directly upon removal from the building tray.

Various embodiments include a method for sintering a multicomponent sinter product comprising: forming a first component consisting of a first material printed with one or more recesses for a second component; forming the second component consisting of a second material; inserting at least a portion of the second component into the one or more recesses of the first component; and shrinking the first component and the second component onto one another by sintering.