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<p>This work introduces an approach for lightweighting gears by incorporating Triply Periodic Minimal Surface (TPMS) cellular structures into gear body construction. A comprehensive finite element analysis was conducted to investigate the performance of various gear types, including spur gears and helical gears with different helix angles, integrated with gyroid and diamond TPMS lattices. A Design of Experiments (DoE) was employed to systematically evaluate the effects of cell size, TPMS type, and gear geometry on stiffness and Von Mises stress. Analysis of Variance (ANOVA) revealed that all parameters significantly influenced the mechanical responses, with gear type and helix angle being identified as the most dominant factors. The results demonstrate that an optimal combination of parameters is required to simultaneously minimize stress and maximize stiffness. This computational study establishes the proposed approach as a viable means of achieving substantial weight reduction in gears, particularly spur gears, while maintaining structural integrity, providing a new mass-lean design framework for gear engineers.</p> Graphical Abstract <p></p>

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Multi-objective optimization of stiffness and strength in lightweight additively manufactured gears with TPMS lattices

  • 期刊论文

  • 发表日期：

    2026年5月11日

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  • Samar Atia,
  • Tawakol A. Enab,
  • Magdy S. Ghattas,
  • Mostafa A. ElBahloul

摘要

This work introduces an approach for lightweighting gears by incorporating Triply Periodic Minimal Surface (TPMS) cellular structures into gear body construction. A comprehensive finite element analysis was conducted to investigate the performance of various gear types, including spur gears and helical gears with different helix angles, integrated with gyroid and diamond TPMS lattices. A Design of Experiments (DoE) was employed to systematically evaluate the effects of cell size, TPMS type, and gear geometry on stiffness and Von Mises stress. Analysis of Variance (ANOVA) revealed that all parameters significantly influenced the mechanical responses, with gear type and helix angle being identified as the most dominant factors. The results demonstrate that an optimal combination of parameters is required to simultaneously minimize stress and maximize stiffness. This computational study establishes the proposed approach as a viable means of achieving substantial weight reduction in gears, particularly spur gears, while maintaining structural integrity, providing a new mass-lean design framework for gear engineers.

Graphical Abstract