“How long would my printed gear last?” New igus online tool predicts running time
Some gearboxes use one or more gear stages to modify torque or speed. Because gears often require complex involute tooth profiles that cannot be designed without specialized tools, igus introduced its gear configurator. More recently, the tool was expanded to include double-gear configurations.
In just a few steps, users enter key parameters such as tooth module, number of teeth, gear width, and the bore diameter. A 3D model is generated automatically and can be exported as a STEP file. By uploading this file to the igus 3D printing service, the configured gear can be ordered directly in igus’s highly durable SLS material, iglide® I3.
To help customers predict the lifespan of their wear-resistant gears, igus has also developed a gear service life calculator. In three simple steps, users receive a clear estimate of service life and application limits for their gear pair.
Three Steps to the Perfect Gear
Step 1: Enter the basic gear parameters—number of teeth, gear width, and module. At this stage, users can select the material: iglide® I3, metal, or another plastic.
Step 2: Provide the operating conditions, including speed and torque for either the large or small gear, depending on which component the values apply to.
Step 3: Define the duty cycle, operating mode, ambient temperature, and safety factor.
Based on these inputs, the online tool calculates the expected service life of the 3D-printed gear in seconds, enabling users to plan maintenance proactively.
Printed Gears Prove Their Strength in Swivel Testing
The high-performance polymer iglide® I3 was specifically developed for producing wear-resistant components such as gears using the SLS (Selective Laser Sintering) process. Extensive testing in igus’s 3,800 m² in-house laboratory confirms its durability and abrasion resistance.
In a swivel test at 1440°, with a speed of 0.1 m/s and torque of 2.2 Nm, a 3D-printed iglide® I3 gear was tested against two POM gears—one injection-moulded and one milled. All gears had 30 teeth and a 16 mm width.
Results:
- The injection-moulded POM gear failed after 4,000 cycles.
- The milled POM gear broke after 12,500 cycles.
- The iglide® I3 gear lasted nearly 20,000 cycles.
For accurate lifetime predictions, engineers can use the free online gear life calculator at:
https://iglidur-gears-expert.igus.tools/requirements?server=1&l=en&c=CA
