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<p>The present work examines the dimensional precision of polymer spur gears produced via Fused Deposition Modeling, benchmarked against conventional metallic gears. A systematic metrological procedure was implemented to quantify profile and pitch deviations, allowing gear classification in accordance with ISO 1328-1 standards using a Coordinate Measuring Machine. PLA gears were manufactured under varying conditions of layer height and printing speed. The findings reveal that 3D-printed gears exhibit considerably larger deviations compared to steel gears, typically falling below ISO class 11. Improved accuracy was achieved with smaller layer heights and reduced printing speeds, while high-speed printing introduced overshoot effects linked to extruder inertia. Further errors originated from the geometric approximation of the involute profile by slicing software. These results underline both the limitations and the potential of FDM in producing functional polymer gears for non-demanding applications, providing insights for future process optimization and gear design.</p>

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Dimensional accuracy assessment of polymeric spur gears fabricated by fused deposition modeling

  • 期刊论文

  • 发表日期：

    2026年3月18日

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  • Christos Papalexis,
  • Dimitrios Krifos,
  • Christos Kalligeros,
  • Nikolaos Bris,
  • Panteleimon Tzouganakis,
  • Georgios Kaisarlis,
  • Antonios Tsolakis,
  • Nickolas Sapidis,
  • Vasilios Spitas

摘要

The present work examines the dimensional precision of polymer spur gears produced via Fused Deposition Modeling, benchmarked against conventional metallic gears. A systematic metrological procedure was implemented to quantify profile and pitch deviations, allowing gear classification in accordance with ISO 1328-1 standards using a Coordinate Measuring Machine. PLA gears were manufactured under varying conditions of layer height and printing speed. The findings reveal that 3D-printed gears exhibit considerably larger deviations compared to steel gears, typically falling below ISO class 11. Improved accuracy was achieved with smaller layer heights and reduced printing speeds, while high-speed printing introduced overshoot effects linked to extruder inertia. Further errors originated from the geometric approximation of the involute profile by slicing software. These results underline both the limitations and the potential of FDM in producing functional polymer gears for non-demanding applications, providing insights for future process optimization and gear design.