Bevel Gear

Bevel Gears

Project Overview

Designed a bevel gear mechanism from scratch to build proficiency in gear geometry, 3D modeling, and additive manufacturing processes. The project focused on developing an accurate and functional gear system using full CAD development in AutoCAD, with emphasis on bevel gear geometry, geometric accuracy, and manufacturability. The assembly demonstrates practical application of gear design principles and mechanical power transmission concepts.

How was the Project Created?

Modeled the complete gear mechanism in AutoCAD using core features such as chamfering, filleting, trimming, extruding, and press-pulling to define precise tooth geometry. Fabricated a physical prototype using additive manufacturing (FDM), slicing the model in Ultimaker Cura and printing on a Creality Sermoon V1 Pro. Applied rapid prototyping and design iteration by troubleshooting initial print failures due to bed calibration, refining the setup, and reprinting to achieve a functional gear. The process reinforced hands-on manufacturing troubleshooting and iterative improvement.

Results

Successfully produced a functional bevel gear prototype using PLA, achieving a low-cost and efficient manufacturing solution. Iterative refinement improved print quality and ensured proper meshing between gears, validating the design’s geometric accuracy and functionality. The final outcome demonstrates strong capability in CAD modelling, gear design, and additive manufacturing, along with a practical understanding of how bevel gear systems are applied in real-world engineering contexts such as automotive and power transmission systems.