Plastic gears: versatile, efficient and silent

maggio 31, 2023

Plastic gears are gaining more and more popularity as an alternative to traditional metal gears. Today we want to tell you about the opportunities offered by the production of plastic gears, the materials used, the strengths and weaknesses, the production technologies and the fields of application.

Plastic materials and their characteristics

The production of plastic gears is mainly based on the use of engineered thermoplastic materials. Common materials include polyamide, polycarbonate, polyoxymethylene, and high-density polyethylene. These materials offer wear resistance, sliding properties, light weight and cost effectiveness.

Here are some of these materials in detail:

Polyamide (PA or nylon): it is a material commonly used for the production of gears, it offers good resistance to wear, friction and abrasion. Furthermore, it is resistant to oils and solvents.
Polycarbonate (PC): offers high resistance to impact and breakage, and is often used for the production of gears that must withstand high loads. However, polycarbonate has lower wear resistance than other plastics.
Polyoxymethylene (POM or Delrin): it is a material with good resistance to wear and fatigue, and is often used for the production of gears that require high dimensional accuracy and a low coefficient of friction.
High-density polyethylene (HDPE): is a plastic with good resistance to abrasion and wear, and is often used for the production of gears in lightly loaded applications.

Pros and cons of plastic gears

Plastic gears have several strengths such as light weight, electrical insulation, ability to reduce noise and vibration, ease of manufacturing and processing, as well as chemical resistance in specific environments. However, it is also important to consider weaknesses such as potential lower wear resistance compared to metallic materials. Possible plastic deformation and limitation of use in high load or extremely high temperature applications are also drawbacks for this product.

Production technologies

They can be produced through a variety of technologies, including injection molding, extrusion, compression molding, cutting, and machining from plastic sheeting. Each technology offers specific advantages in terms of accuracy, design complexity and size.

Here is specifically how we produce them:

Injection molding - the most common technology for manufacturing plastic gears. The injection molding process involves melting plastic and injecting it into a mold, where it solidifies and takes on the desired gear shape.
Extrusion: This is used to produce gears with a constant cross section, such as gear wheels. The plastic is melted and pushed through a die with the desired gear shape.
Compression Molding: It is used to produce gears of large size or complex shapes. The plastic is melted and poured into a mold, where it solidifies and takes the shape of the gear.
Cutting and Processing: Used to produce gears from plastic sheets. The sheet is cut into the shape of the gear and then machined to achieve the desired teeth and finish.

Fields of application

Plastic gears find applications in various industries, such as automotive, electronics, aerospace, packaging, food processing, electric tools, and mechanical engineering.

In particular:

Automotive: They are used in various auto components to reduce weight, noise, improve efficiency and reduce costs.
Electronics: They are used in many electronic devices, such as printers, copiers and scanners, to transfer and regulate the movement of components.
Aerospace: They are used in aircraft components to reduce weight and improve performance.
Packing: They are used in packaging, food and beverage processing machines to regulate the movement of moving parts.
Food industry: They are used in many food production and processing machines
Power Tools: These are used in many portable power tools, such as drills and screwdrivers, to regulate the movement of moving parts.
Mechanical industry: They are used in many other mechanical components and systems.

Do you want to know more or understand if you can apply plastic gears to your project? Contact us for technical advice

Plastic gears: versatile, efficient and silent

Plastic materials and their characteristics

Pros and cons of plastic gears

Production technologies

Fields of application

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