Determination of optimal parameters for rapid prototyping of the involute gears

Nowadays, rapid prototyping technologies are available at very affordable prices. This is the main reason why they are being used in almost all industry sectors. 3D printers are currently being widely used for rapid prototyping and development of the new products. However, taking into account the permanent progress of rapid prototyping materials mechanical characteristics (usually different kinds of plastics), 3D printers are sometimes used even for production of the failed parts replacements – operating at the low load and rotational speed conditions. This is the main goal of this paper – to establish optimal 3D printing parameters (printing direction, layer height and percent of infill) which will allow printed gears to replace failed steel gears, for at least some time, enough for spare steel gears to be produced and delivered on site. Taking into account previously mentioned facts, the application of the 3D printed gears can potentially provide the reduction of maintenance delays in different industrial facilities (factories, workshops, etc.) which will consequently lead to significant energy and financial savings.