Method of forming spline gears and assembling a dual spline gear

A method of forming spline gears and assembling a dual spline self-aligning gear, comprising:

• forming a first spline gear and a second spline gear by hobbing first and second thermoplastic spline gear blanks to form the first and second spline gears, wherein the hobbing forms a plurality of evenly spaced outer spline teeth and an inner ring comprising a plurality of evenly spaced inner spline teeth alternating with a plurality of inner spline grooves on an outer circumference of the first and second thermoplastic spline gear blanks;
• receiving a toothed ring gear having a plurality of evenly spaced outer gear teeth located on an outer circumference, wherein the tooth ring gear is made of thermoplastic material, wherein an inner ring of the toothed ring gear is configured with a plurality of evenly spaced inner gear teeth alternating with a plurality of inner gear grooves, wherein each of the inner gear grooves includes a radially extending rib centrally located between each inner gear tooth;
• coating each of the inner gear teeth and the inner gear grooves with a first glue layer;
• inserting, from a first side of the toothed ring gear, the first spline gear between the inner gear grooves of the toothed ring gear until each outer spline tooth abuts the radially extending rib;
• and
• inserting, from a second side of the toothed ring gear, the second spline gear between the inner gear grooves of the toothed ring gear until each outer spline tooth abuts the radially extending rib.