Failure analysis of nylon gears made by additive manufacturing

Additive manufacturing enables fast manufacturing of polymer gears directly from a 3D model. Failed polymer gears can be replaced easily and quickly using many different materials. Mechanical and thermal characteristic of gears manufactured using additive manufacturing are mostly dependent on selected manufacturing parameters and material. In this research, the influence of the most important manufacturing parameter (infill percentage) on failure types and service life of additive manufactured nylon gears is experimentally investigated. The experimental tests were carried out using a custom-made gear testing device. Samples with 20, 40, 60, 80 and 100% of infill volume were tested. Infill type, shell thickness, and manufacturing speed were the same for all samples. Service life of gears was tested and failure types were characterized.

Automated summary

Additive manufacturing allows for fast production of polymer gears directly from a 3D model, with the ability to easily replace failed gears using different materials. The mechanical and thermal characteristics of these gears depend on the selected manufacturing parameters and material. This research experimentally investigates the influence of the most important manufacturing parameter, infill percentage, on the failure types and service life of additive manufactured nylon gears.