Square shaft Round hole

Getting the gears to press fit on the shaft was a 6 month endeavor.  I was using 2 and 3mm round shafts because I wanted to use an off the shelf 0.5M gear to dock with the gear on the motor. 

Unfortunately, if I glued it, it came loose. If I press fit it, it would crack or come loose.

I finally realized that I actually could cut the 0.5M gear on the laser cutter. It just took some seam compensation of 0.1mm to make sure the kerf of the laser cutter did not make the teeth too small.

Once I found this out, I could make square shafts and square holes in the gears. I could make a stepped shaft so it would sit axially in the correct position. I made some clips to hold the gears on the outside of the gearbox although they could use a little optimization.

Now I have very little friction and have completely eliminated the slippage issue.

Pictures to come.