A Comprehensive Study on Challenges in Gear Manufacturing using Fused Deposition Modeling
Year: 2025
Type: article
Abstract: Aim: This paper aims to explore the challenges faced in manufacturing gears using Fused Deposition Modeling (FDM), an additive manufacturing technique, and to identify strategies for optimizing the process. Gears are integral to numerous mechanical systems, and their manufacturing demands precision, strength, and durability. However, applying FDM for gear production introduces unique challenges related to the technology’s inherent layer-by-layer construction. This paper delves into these barriers, focusing on dimensional accuracy, material limitations, and surface finish. Furthermore, it seeks to bridge the gap between current capabilities and the requirements for functional, high-performance gears using FDM. Methodology: The study conducts a comprehensive review of the literature on FDM technology, focusing on its application in gear production. It analyzes challenges such as dimensional accuracy, material properties, surface finish, and long-term durability, and highlights advancements in materials, process parameters, and post-processing techniques. Major Findings: Key challenges in FDM gear production include issues with mechanical strength, wear resistance, and surface roughness. Recent advancements, such as material innovations and process optimization, show potential in addressing these hurdles and improving the feasibility of FDM for gear manufacturing. Value: This paper provides a focused review on the application of FDM in gear manufacturing, offering practical insights and recommendations for researchers and practitioners. By addressing critical barriers, it contributes to advancing the use of FDM in producing functional gears.
Institution: Sandip Foundation
Language: English
Subfield: Industrial and Manufacturing Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
OpenAlex ID: W7128215212