Had a few too many beers last night…!:ror: The idea that was in my head was it would be cool if we could come up with a splined shaft & hex. Tighten it down with a bolt and a spacer (As a buffer between the nut and hex) before installing the wheels? Shim as needed? Unless it’s like the picture and can be seated at a predetermined point. Oh yeah"thumbsup".
<a href="https://ibb.co/WydRsVL"><img src="https://i.ibb.co/58zJ2KP/D7-A4177-C-E97-B-4-DB7-AD2-C-AFF820-A80240.jpg" alt="D7-A4177-C-E97-B-4-DB7-AD2-C-AFF820-A80240" border="0"></a>
There's good...and bad...in your design idea. In some ways, your splined shaft isn't really much different from the traditional hex. Both rely on 'teeth' to transfer rotational power from hex to wheel. If you think of a spline as having "concave" and "convex" teeth, you could say that the traditional hex has "convex" teeth.
The 'good' is that it would probably be a lot easier getting the wheels pressed onto the spline (I'm sure we've all experienced how difficult it can sometimes be getting wheels seated onto the hex). Unfortunately, and realistically, that's probably the extent of the 'good'.
Since most wheels tend to be plastic (racers ALWAYS use plastic wheels), this leads to another problem - the greater the number of 'teeth', the more likely, and the faster, the wheel will shear. This is because, the greater the number of 'teeth', the smaller the teeth would be. A hex has, in essence, 6 'teeth', so that possibility is greatly minimalized. With a splined design, the greater the number of teeth, the smaller each tooth is, thus the less holding power they have, and the shorter the life of the wheel would be.
Notice I haven't even mentioned about how the spline would be held in place in the axle stub. When you say "tighten it down with a bolt", I assume you're either referring to a grub screw (goes into a threaded hole on the side of the spline, tightens against the axle stub, holding the spline in place), or a threaded pin (goes through both sides of the spline, as well as the pin hole in the axle stub, with one side of the spline's hole also being threaded). In either of these, as with a pin being held in place by a traditional hex, the rotational power is still transferred via the pin, thus nothing is gained.
Now, if the spline & axle stub were a single piece (ie. machined), completely eliminating the need for a hex pin, then we'd be getting somewhere. Such a design would be MUCH stronger than the current axle stub/pin/hex method ..except that there'd still be the tooth-shearing problem described in my 2nd paragraph. Taking that idea one step further...one that would truly resolve both problems (ie. snapping/shearing the axle stub where the pin passes through, AND how/where rotational power is transferred)...would be to have a one-piece axle stub-hex, but keeping the traditional hex design. Unfortunately, I don't see this ever happening, as people sometimes like to adjust the vehicle width, and this is topically done through the use of different width hexes...thus, we're back to square one.
There are a lot of great solutions to these problems...but, until someone can come up with a realistic way of resolving them all, the traditional axle stub/hex pin/hex design will probably remain the same. This is the design that's been used since the beginning on RC...it's not perfect, but it works. Now, if you have a vehicle that you are 100% certain you'll never adjust the width on, you could always try welding the hex (from the vehicle side, obviously, not the wheel side) to the axle stub (I'm not suggesting, or advocating, this, it's just another idea).
~ More peace, love, laughter & kindness would make the world a MUCH better place [emoji1690]