Dimensional Precision of Plastic Gear Tooth Profiles Produced by 3D Printing

Plastic spur gears have gained significant attention in the last couple of decades in all industries where rotational motion is involved. Plastic gears have the advantages of light weight, shock absorption, low operation noise levels, and functioning without lubrication. However, the manufacturing precision of gears and gear tooth profiles has a significant effect on the lifetime of the gears. The aim of this study was to investigate the effect of 3D printing (Fused Deposition Modeling) parameters on the precision of the tooth profile. To study the effect of layer thickness, printing speed, and infill parameters, the Box–Behnken experimental design was utilized. The results show that the mean profile deviation was 0.067 ± 0.02 mm, and the printing speed had a statistically significant effect on the precision of the tooth profile. Plastic 3D printing provides more design freedom; therefore, it is a promising technology for low production volumes and special geometry gear manufacturing.