Geometric Accuracy and Dimensional Precision in 3D Printing-Based Gear Manufacturing: A Study on Interchangeability and Forming Precision

This paper investigates the geometric interchangeability and dimensional precision of parts fabricated using Fused Deposition Modeling (FDM), with a focus on gear manufacturing. By employing a substrate and two spur gears as test components, critical process parameters, including layer thickness, extrusion speed, and print temperature, were optimized to achieve enhanced accuracy. Geometric and dimensional tolerances such as straightness, roundness, and surface roughness were systematically evaluated using advanced metrological techniques. The results indicate that larger components demonstrate higher precision, with deviations for large and pinion gears ranging between -0.045 and 0.060 mm, and -0.150 and 0.078 mm, respectively. Analysis reveals that the anisotropic nature of the FDM process and thermal shrinkage significantly impact accuracy, particularly in smaller features. Residual stress analysis reveals that smaller components formed via FDM exhibit higher stress concentrations and dimensional deviations due to voids and uneven thermal contraction, whereas larger components and flat substrates achieve better stress distribution and precision. The findings suggest that reducing material shrinkage coefficients and optimizing process parameters can enhance part quality, achieving dimensional tolerances within ±0.1 mm and geometric consistency suitable for practical applications. This research highlights the potential of FDM for precision manufacturing and provides insights into improving its performance for high-demand industrial applications.