Custom – made wear – resistant nylon gear set by 3D printing

Description

(1) Scope of Customization Services

• Material & Process Adaptation:
  • Core Materials:
    • PA11/PA12 Nylon: High wear resistance and chemical resistance, suitable for high-load gear applications (e.g., industrial transmission gears).
    • PA12GB: Glass bead-reinforced nylon with enhanced strength and rigidity, ideal for impact-resistant gears.
  • Extended Materials: Supports ABS (high gloss), PC (high temperature resistance), TPU (elastomers), etc., for specialized needs (e.g., medical-grade gears, heat-resistant gears).
• Process Options:
  • SLS/MJF 3D Printing:
    • SLS: Support-free, suitable for complex gear internal holes and tooth profiles, high surface precision (Ra 0.1-3.2), ideal for low-volume production.
    • MJF: Fast prototyping, high material efficiency, multi-material mixing support, with post-processing options (dyeing, surface hardening).
  • Other Processes: FDM (low-cost prototyping), SLA (high-precision resin gears), metal 3D printing (stainless steel/aluminum gears).
• Structural Customization:
  • Supports spur gears, helical gears, bevel gears, etc., with customizable parameters (tooth width, module, pressure angle).
  • Provides gear set linkage design for precise transmission ratios, with options for embedded metal bushings or bearings.

(2) Production and Quality Advantages

• Equipment and Precision:
  • Equipped with 100+ 3D printers (e.g., SLA750, FARSOON 401 metal printers), achieving ±0.001mm precision for metal parts and ±0.005mm for plastic parts.
  • Uses 3D scanning inspection (±0.002mm accuracy) for full-dimensional verification against design drawings, ensuring tooth profile errors <0.01mm.
• Quality System:
  • Full-Process Control: Incoming material testing (melt index, strength) → Print process monitoring (layer thickness, temperature) → Post-processing (deburring, curing) → 100% inspection (CMM for surface roughness and meshing clearance).
  • Life Testing: Provides gear fatigue test reports (e.g., 500 hours of continuous operation with <0.005mm wear), with nylon gear service life exceeding 10,000 hours.
• Environmental Compliance: Materials are RoHS-certified, nylon powder is recyclable, and production is free of hazardous emissions.

(3) Service and Delivery Advantages

• Design & Prototyping:
  • Accepts customer-provided 3D models or 2D drawings; for customers without drawings, offers sample scanning (3D model within 24 hours) and rapid prototyping (samples ready in as fast as 3 days).
  • Engineering team provides DFM (Design for Manufacturability) analysis to optimize gear structures (e.g., hollow tooth design reduces material usage by 30%).
• Flexible Collaboration:
  • Low-Volume Customization: 1 piece minimum order, ideal for R&D prototyping (e.g., drone gear prototypes), 50% lower cost than traditional machining.
  • Mass Production: 1,000,000 pcs/month capacity, tiered discounts for orders over 1,000 pieces, with support for mold transition (from 3D printing to injection molding).
• Global Service Network:
  • Main export markets: USA, Canada, Netherlands; offers DDP door-to-door service (7 days to North America) and negotiable FOB Xiamen port pricing.
  • Response time ≤2 hours, with real-time printing progress tracking (e.g., layer-rendering videos, live inspection data updates).

(4) Customer Cases and Reputation

• Typical Applications:
  • Developed PA12GB helical gear sets for a U.S. industrial equipment manufacturer’s automated production line, with wear rate <0.005mm per 1,000 hours of testing.
  • Created medical-grade nylon gears for a German medical enterprise, FDA-certified for use in surgical instrument precision drives.
• Market Feedback:
  • 99% positive rating from 103 reviews, praised for precision (gear transmission error <0.5%) and delivery speed (urgent orders processed within 48 hours).
  • 85% repurchase rate, with long-term clients including Tesla supply chain companies, 3D printing service platforms, and aerospace R&D institutions.