Custom Gears
A professor once told an engineering design class I was in, "Do everything you can to avoid designing custom gears.". I have followed this wise advice (Thank you Dr. Leckie!), but still have occasionally had the need to implement some custom gearing.
Sometimes the design / spatial constraints require something custom, such as for medical robots, small optical-mechanical systems, etc.
This is not as bad as it sounds once you've done a bit of gear train design. "Off the shelf" gear manufacturers can make slightly different versions of their gears when the manufacturing volume warrants this. (A few more teeth / different pitch diameters to fit the specific design requirements, different face widths, custom shaft attachment methods, etc...)
-James Cuevas, Precision Mechanical Design
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