Finite Element Analysis of 3D-Printed Gears: Evaluating Mechanical Behaviour Through Numerical Modelling

In the course of the 3D printing process, the occurrence of imperfect structures is attributable to the rapid cooling of molten polymer. In this study, gears were manufactured from PA6 using a dedicated 3D printer, and their performance was analyzed using finite element analysis (FEA), validated by wear tests. A subset of the gears was subjected to annealing heat treatments to investigate their influence on the behavior of the material. The novelty of this study lies in the correlation of the effects induced by heat treatment with the stress distribution, wear, and service life of 3D-printed gears. This provides useful information for optimizing polymer gears for engineering applications. This study's novelty lies in highlighting the influence of heat treatments on wear behaviour and mechanical stress factors, offering new insights into the optimisation of 3D-printed polymer gears.