Case Study 02

Project Description

Design and development of a functional Bevel Gear Differential System using SOLIDWORKS, followed by 3D printing, assembly, and physical testing to validate the mechanism in real-world conditions.

The Challenge

The goal was to create a working differential that demonstrates realistic power transmission and speed differentiation between the wheels while maintaining proper gear engagement and shaft alignment.

Mechanical Design

The system was developed in SOLIDWORKS, with a focus on bevel gear geometry, gear ratio, shaft alignment, bearing support, housing design, and smooth mechanical motion.

From CAD to Reality

The complete assembly was 3D printed, assembled, and physically tested, allowing the digital design to be validated as a functional mechanical mechanism.

The Result

A fully functional differential prototype demonstrating how mechanical design, gear systems, and additive manufacturing can transform a CAD concept into a real working mechanism.

Concept → CAD → 3D Printing → Assembly → Functional Validation

My Role

Mechanical Design | Gear System Design | Bearing & Housing Design | Assembly | Physical Validation

Key Takeaway

A successful mechanical design doesn't stop at the CAD model — it has to work in the real world.