>>2004546> I think this is quite a big angle for a cardan joint. (As far as I remember from uni). And if you are using a single joint and not a pair of joints with correct phasing, then you will have problems with vibrations and maybe even with loosing traction if this is for driving rear wheel .As far as my research goes I've read that cardans are good for up to 45°. It's not coincidence that I've chosen 40°. My idea was that the suspension is a bit lifted so the wishbones sit at 15° from the horizontal plane, I also accounted for up to 25° of maximum leaning angle, therefore, adding up those numbers I'd need 40°. I wanted it lifted like that so it's more visible to cars over the hood. But I guess sacrifices can be made and the wishbone horizontal angles can be reduced as well as the leaning angle by quite a bit.
>An interesting idea is also (semi) spherical gears. It works like normal gears, except that angles between axis can change. I 3d printed a plastic sample a couple years ago, but I didn't have an application for it, so I didn't go any deeper in that topic.>Of course this is entirely custom job, but even metal 3d printing is getting cheaper, depending on your budget, untested design, etc.... something to think about.I don't know what to feel about spherical gears, they are not used much, there must be a reason. Also to keep the teeth touching the mechanism must be relatively heavy.
I do want to use 3d printing for this project, but not in the way you suggested, but to make composites:
https://youtu.be/nhqAhYOdGNcAlso the other day after an hour of YouTube research I figured out how to make a simple lockable differential that also should be not much heavier than an open one. The locking mechanism can also be used to lock up a freewheel and engage/disengage a motor, so I'm quite happy with that.