Design of Injection Molded Plastic Gears

This project aims at the development of a guideline for the suitable design of plastic gears, considering function, material and technology, using a physical and experimentally validated approach.

Plastic gears show several advantages compared to metallic gears such as lower weight, dry run capability or the potential for cost-effective mass production. However, disadvantages such as inferior mechanical and thermal properties and less geometrical precision need to be compensated by constructive means. Present design methods have a very limited applicability, since several plastic specific properties such as viscoelasticity or damage mechanisms are neglected. Therefore, in this project a multi physical modelling approach is carried out and experimentally validated, which should be used as a basis for applicable design methods. Current works at IVW focus on the tribologi
cal and mechanical material characterization of short glass fiber reinforced thermoplastics and the analysis of fiber orientation in gears as input parameters for the modeling approach developed jointly with the Institute of Machine Elements, Gears, and Transmissions at the Technical University Kaiserslautern.

Field of competence

Industry sectors

Project status

  • Current



Stefan Schmidt

Scientific Staff Crash & Energy Absorption

Telephone: +49 631 2017 274

Room: 58/240


Andreas Gebhard

Manager Tribology

Telephone: +49 631 2017 342

Room: 58/433


The project “Design of Injection Molded Plastic Gears” is funded by the Federal Ministry of Economic Affairs and Energy on the basis of a decision by the German Bundestag (funding reference 20379N).