Fabricating Lightweight Gear Using 3D Printing and Topology Optimization

This research deals with the design and fabrication of a lightweight gear having honeycomb body structure. A honeycomb design is a complex structure that cannot be produced using traditional manufacturing methods. Selective Laser Melting (SLM) technology, on the other hand, enables the direct production of such innovative lightweight structures from their CAD models. The gear body structure was designed and optimized by employing topology optimization, and it was fabricated by AlSi10Mg alloy utilizing SLM. Numerical results showed that the honeycomb structure of the gear body has sufficient strength to carry the loads, while the practical example demonstrates the benefit of using 3D printing for lightweight products with intricate designs.