3D printing has become a go-to method of production and testing for engineers, hobbyists, and amateur inventors. Since gears are typical components of machines with moving parts, it’s natural to think that 3D printing gears to serve your prototype machine is the most reliable and cost-efficient method to see if your design will work.
3D printing is certainly the cheapest way to make prototype gears, whether you’re using a scaled-down model or a full-sized one, but is it reliable for testing the feasibility of your work?
Choosing the Right Software
First, you need to make sure you choose the right modeling software. Most 3D printed models begin with this software-based sculpting process. You may be able to find templates and pre-made gear designs that fit your intended model, but if you don’t, you’ll need to rely on external design software to produce your printable model. There are many types of software available, some of which are specifically intended for gear design. These niche-focused design tools are recommended for people unfamiliar with the complexities of gear mechanics.
Materials
You’ll also need to consider which materials you’ll use in 3D printing. The most available and cheapest are ABS and PLA plastics, both of which are easily malleable. PLA is typically easier to print, but ABS is stronger and more durable. You may also be able to find a 3D printer that can print your gear with other materials, such as metal (but prepared for it to be more expensive).
The Problems
There are a few problems you’ll face when 3D printing gears:
- Post-printing work. All 3D printed materials will need some work once they’re “completed,” including trimming off excess components and correcting small imperfections.
- Center hole shrinkage. Depending on your design, you may also experience some center hole shrinkage after printing, which could interfere with your precision fits.
- Scale. Gear functionality depends on many variables, including weight and positioning, which may change at a higher scale (and render your prototype ineffective).
- Precision. No matter what, 3D printing won’t be as precise as professional gear manufacturing.
So can you use 3D printing for prototype gear manufacturing? If you’re familiar with the process’s strengths and weaknesses, it’s definitely possible. Otherwise, contact a professional gear manufacturer like Federal Gear to make sure your project gets done right.