Differential Gearbox Pt 3 - (The One Part Every Differential Needs and Nobody Talks About)

Learn how to design a splined differential shaft in SolidWorks — Part 3 of my full differential gearbox build, continuing on from the housing and flange in Parts 1 and 2. 📺 Watch Part 1 (Differential Housing) here:    • Design a Differential Gearbox Housing in S...   📺 Watch Part 2 (Differential Flange) here:    • Design a Differential Flange in SolidWorks...   In this video, I walk through the process of modeling the shaft: ✅ Revolve the main shaft body from a stepped diameter profile ✅ Sketch and cut a single spline tooth profile at one end ✅ Circular Pattern the cut around the shaft to complete the spline set ✅ Repeat the spline pattern on the opposite end ✅ Fillet the diameter steps for a realistic, stress-relieved finish This shaft is what actually transmits torque through the assembly — the splines on each end are what will eventually engage with mating parts elsewhere in the build, so getting the spline profile and step diameters accurate here matters for the whole gearbox to function correctly, not just look right. ⏱️ Chapters 00:00 Final Part Preview 00:20 Sketching the stepped shaft body 09:00 Sketching the stepped shaft body 10:00 Cutting the first spline tooth 15:40 Patterning the splines on one end 17:00 Patterning the splines on the other end 20:30 Fillets and final cleanup 🔧 Commands used: Revolve, Extruded Cut, Circular Pattern, Fillet 📌 Subscribe to Learn CAD with Billu to follow the rest of the differential gearbox build. #SolidWorks #CADTutorial #MechanicalEngineering #Projects