Determination of the most influential factors on the quality of resin gears manufacturing

The manufacture of industrial parts using silicone molds is becoming more frequent due to their versatility, durability, and precision, particularly in the production of complex components. One specific application is the manufacture of gears, which play a fundamental role in high-performance mechanical systems, where geometric accuracy is essential. Gears produced from resins offer several advantages such as efficient tribological performance, load resistance, noise reduction, and non-magnetic properties. The main goal of this paper is to determine the main factors affecting the final quality of resin gears by analyzing two principal gear quality parameters: teeth profile (ffα) and helix deviation (ffβ). This work includes a global analysis of all contributing factors influencing the final quality of gears manufactured. One of the main conclusions obtained is that gear quality depends on a combination of factors, such as mold properties, choice of resin, the manufacturing process, and the quality of the original model. As a result, two regression equations have been developed, relating all influencing factors to the two gear quality parameters (ffα and ffβ). Different response surfaces have been obtained, enabling the definition of the required quality level of the model to achieve reproductions with certain ffα and ffβ values suitable for the intended application conditions.