Lightweight Plastic Gear Body using Gyroid Structure for Additive Manufacturing

Nowadays, plastic gears are more commonly used. The Triply Periodic Minimal Surfaces (TPMS) structure can perfect the design to reduce weight but still achieve the desired workability criteria. It can also be adjusted more easily and scientifically than the empirical structure optimization based on experience. Currently, the fabrication of gears with complex internal structures such as TPMS is possible thanks to 3D printing technology. This study investigates the mechanical properties of a TPMS structure when applied to Polyetheretherketone (PEEK) plastic gears. The research content includes displacement, deformation, and Von-mises stress to evaluate the stiffness and strength of gears. The structure used to optimize the gear mass is the Gyroid structure, developed in the cylindrical cell map and studied in the paper. The goal of the research is to apply the Gyroid structure to optimize mass while still ensuring gear performance. This study not only offers new insight into the importance of the control variables for TPMS structures but also provides a mass lean process for gear designers. It uses experimental design methods to choose a suitable topology structure, and the final research result is a regression equation, which clearly shows the close relationship between the volume reduction and displacement with the specified control variables of the unit cell. From there, it is possible to determine the proper amount of material reduction while ensuring the working ability of the gear transmission.