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<p>The emergence of 3D printing technology has revolutionized the manufacturing sector, offering exceptional design flexibility and customization within the context of Industry 4.0. This study explores the application of 3D printing to create high-performance spur gears made from carbon fibre-reinforced nylon for robotic systems. Leveraging the capabilities of 3D printing, the research aimed to design, fabricate, and assess the performance of these gears. Gear designs were developed using Computer-Aided Design (CAD) software, fabricated through material extrusion 3D printing, and then subjected to mechanical testing to evaluate properties such as contact stress and bending strength. Finite Element Analysis (FEA) was employed to simulate and predict these mechanical properties, with results showing predicted contact stress and bending strength of 4.72&#xa0;MPa and 261.96&#xa0;MPa, respectively. Experimental results closely aligned with measured values for contact stress and bending strength of 4.50&#xa0;MPa and 250.12&#xa0;MPa, respectively. This study uniquely demonstrates that finite element predictions for CFR-nylon gears closely align with experimental results, with errors of less than 5%. The findings underscore the novelty of employing CFR-nylon in 3D-printed gear applications and highlight its potential for lightweight, high-performance use in robotic systems and additive manufacturing.</p>

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Comparative Analysis of Carbon Fibre-Reinforced Nylon Composite Gear Performance: Numerical and Experimental Approaches

  • 期刊论文

  • 发表日期：

    2025年11月24日

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  • Likhith Pujari,
  • Mantesh Basappa Khot

摘要

The emergence of 3D printing technology has revolutionized the manufacturing sector, offering exceptional design flexibility and customization within the context of Industry 4.0. This study explores the application of 3D printing to create high-performance spur gears made from carbon fibre-reinforced nylon for robotic systems. Leveraging the capabilities of 3D printing, the research aimed to design, fabricate, and assess the performance of these gears. Gear designs were developed using Computer-Aided Design (CAD) software, fabricated through material extrusion 3D printing, and then subjected to mechanical testing to evaluate properties such as contact stress and bending strength. Finite Element Analysis (FEA) was employed to simulate and predict these mechanical properties, with results showing predicted contact stress and bending strength of 4.72 MPa and 261.96 MPa, respectively. Experimental results closely aligned with measured values for contact stress and bending strength of 4.50 MPa and 250.12 MPa, respectively. This study uniquely demonstrates that finite element predictions for CFR-nylon gears closely align with experimental results, with errors of less than 5%. The findings underscore the novelty of employing CFR-nylon in 3D-printed gear applications and highlight its potential for lightweight, high-performance use in robotic systems and additive manufacturing.