The function of the worm gear mechanism is to rotate the Kinora reel. The rotating handle is connected to the worm gear via the worm shaft. The original gear has fifty teeth, allowing for the full rotation of a reel.
Since the FFF 3D printer at the Engineering Lab cannot print materials smaller than 0.4mm, we had to enlarge the worm gear to 3D print the replica and maintain the original functionality of the system. We also added an extra bearing at the end of the worm shaft to prevent bending during rotation.
To resolve friction issues in the worm gear mechanism that caused the worm shaft to bend at the end and disconnect from the worm gear, we 3D-printed the worm gear and worm shaft using a stronger material: Onyx nylon. We also increased the size of the guidance and axis and added several bearings, screws and spacers for increased stability and support, along with other design modifications.