Measured dimensional deviations of gear features produced by Laser Powder Bed Fusion in cobalt-chrome and Bound Metal Deposition in 4140-steel. Values are compared to the original CAD design reference, with deviations assessed against international ISO tolerance standards for machining
| Part name | Feature | Reference value (from CAD) | Measured value (from 3D scanning) | Deviation (mm) | ISO tolerance (mm) |
|---|---|---|---|---|---|
| LPBF CoCr | Lower hub diameter | 50.2053 | 49.9603 | −0.245 | ±0.2–0.3 |
| Bore diameter | 19 | 18.9785 | −0.02141 | ±0.021 | |
| Upper hub diameter | 47.7451 | 47.55 | −0.1952 | ±0.2–0.3 | |
| Gear height | 15.9086 | 15.8168 | −0.0918 | ±0.2–0.3 | |
| Upper hub height | 13.1366 | 12.8057 | −0.3308 | ±0.2–0.3 | |
| Lower hub height | 4.3588 | 4.2999 | −0.0589 | ±0.2–0.3 | |
| Tooth thickness | 5.6749 | 5.7129 | 0.038 | ±0.02–0.1 | |
| Circular pitch | 8.9926 | 9.0718 | 0.0792 | ±0.02–0.1 | |
| Keyway length | 6 | 5.9852 | 0.0148 | ±0.2–0.3 | |
| Keyway width | 3.5153 | 3.5258 | 0.0105 | ±0.043 | |
| BMD 4140 | Lower hub diameter | 50.2053 | 50.0379 | −0.1674 | ±0.2–0.3 |
| Bore diameter | 19 | 19.109 | 0.109 | ±0.021 | |
| Upper hub diameter | 47.7451 | 47.5057 | −0.2394 | ±0.2–0.3 | |
| Gear height | 15.9086 | 15.8507 | −0.0579 | ±0.2–0.3 | |
| Upper hub height | 13.1366 | 13.1695 | 0.033 | ±0.2–0.3 | |
| Lower hub height | 4.3588 | 4.432 | 0.0732 | ±0.2–0.3 | |
| Tooth thickness | 5.6749 | 5.5317 | 0.1432 | ±0.02–0.1 | |
| Circular pitch | 8.9926 | 8.9746 | −0.018 | ±0.02–0.1 | |
| Keyway length | 6 | 5.9775 | 0.0225 | ±0.2–0.3 | |
| Keyway width | 3.5153 | 3.5012 | 0.0141 | ±0.043 |
| Part name | Feature | Reference value (from | Measured value (from 3D scanning) | Deviation (mm) | |
|---|---|---|---|---|---|
| Lower hub diameter | 50.2053 | 49.9603 | −0.245 | ±0.2–0.3 | |
| Bore diameter | 19 | 18.9785 | −0.02141 | ±0.021 | |
| Upper hub diameter | 47.7451 | 47.55 | −0.1952 | ±0.2–0.3 | |
| Gear height | 15.9086 | 15.8168 | −0.0918 | ±0.2–0.3 | |
| Upper hub height | 13.1366 | 12.8057 | −0.3308 | ±0.2–0.3 | |
| Lower hub height | 4.3588 | 4.2999 | −0.0589 | ±0.2–0.3 | |
| Tooth thickness | 5.6749 | 5.7129 | 0.038 | ±0.02–0.1 | |
| Circular pitch | 8.9926 | 9.0718 | 0.0792 | ±0.02–0.1 | |
| Keyway length | 6 | 5.9852 | 0.0148 | ±0.2–0.3 | |
| Keyway width | 3.5153 | 3.5258 | 0.0105 | ±0.043 | |
| Lower hub diameter | 50.2053 | 50.0379 | −0.1674 | ±0.2–0.3 | |
| Bore diameter | 19 | 19.109 | 0.109 | ±0.021 | |
| Upper hub diameter | 47.7451 | 47.5057 | −0.2394 | ±0.2–0.3 | |
| Gear height | 15.9086 | 15.8507 | −0.0579 | ±0.2–0.3 | |
| Upper hub height | 13.1366 | 13.1695 | 0.033 | ±0.2–0.3 | |
| Lower hub height | 4.3588 | 4.432 | 0.0732 | ±0.2–0.3 | |
| Tooth thickness | 5.6749 | 5.5317 | 0.1432 | ±0.02–0.1 | |
| Circular pitch | 8.9926 | 8.9746 | −0.018 | ±0.02–0.1 | |
| Keyway length | 6 | 5.9775 | 0.0225 | ±0.2–0.3 | |
| Keyway width | 3.5153 | 3.5012 | 0.0141 | ±0.043 |
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