International Journal of Trend in Scientific Research and Development (IJTSRD)

Volume 4 Issue 1, December 2019 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470

Design and Manufacturing of Sprocket using

Additive Manufacturing Technology
B. Raghu1, G. Sai Hitheswar Reddy2, D. Rishikesh2, K. Aseem Kumar2
1Assistant
Professor, 2UG Scholar,
1,2Department of Mechanical Engineering, Guru Nanak Institute of Technology, Rangareddy, Telangana, India

ABSTRACT How to cite this paper: B. Raghu | G. Sai

Additive manufacturing, often referred to as 3D printing, has the potential to Hitheswar Reddy | D. Rishikesh | K. Aseem
vastly accelerate innovation, compress supply chains, minimize materials and Kumar "Design and Manufacturing of
energy usage, and reduce waste. Originally developed at the Massachusetts Sprocket using Additive Manufacturing
Institute of Technology in 1993, 3D printing technology forms the basis of Z Technology"
Corporation’s prototyping process. 3DP technology creates 3D physical Published in
prototypes by solidifying layers of deposited powder using a liquid binder. By International Journal
definition 3DP is an extremely versatile and rapid process accommodating of Trend in Scientific
geometry of varying complexity in hundreds of different applications, and Research and
supporting many types of materials. Z Corp. pioneered the commercial use of Development (ijtsrd),
3DP technology, developing 3D printers that leading manufacturers use to ISSN: 2456-6470, IJTSRD29464
produce early concept models and product prototypes. Utilizing 3DP Volume-4 | Issue-1,
technology, Z Corp. has developed 3D printers that operate at unprecedented December 2019, pp.177-182, URL:
speeds, extremely low costs, and within a broad range of applications. This https://www.ijtsrd.com/papers/ijtsrd29
paper describes the core technology and its related applications. 464.pdf
Additive manufacturing, often referred to as 3D printing, is a new way of
Copyright © 2019 by author(s) and
making products and components from a digital model. Like an office printer
International Journal of Trend in Scientific
that puts 2D digital files on a piece of paper, a 3D printer creates components
Research and Development Journal. This
by depositing thin layers of material one after another, only where required,
is an Open Access article distributed
using a digital blueprint until the exact component has been created. Interest
under the terms of
in additive techniques is growing swiftly as applications have progressed from
the Creative
rapid prototyping to the production of end-use products. Additive equipment
Commons Attribution
can now use metals, polymers, composites, or other powders to “print” a range
License (CC BY 4.0)
of functional components, layer by layer, including complex structures that
(http://creativecommons.org/licenses/by
cannot be manufactured by other means.
/4.0)
By eliminating production steps and using substantially less material,
‘additive’ processes could be able to reduce waste and save more than 50% of
energy compared to today’s ‘subtractive’ manufacturing processes, and reduce
material costs by up to 90%. The use of additive manufacturing can potentially
benefit a wide range of industries including defence, aerospace, automotive,
biomedical, consumer products, and metals manufacturing.
In this project, parametric model is done in Catia V5R20 and 3D- printing is
done in Cura software.

KEYWORDS: Additive Manufacturing, Prototypes, 3D-Printing, Deposition, Binder,

Rapid Prototyping, Subtractive manufacturing
I. INTRODUCTION
3D printing is the type of Additive Manufacturing is any of were not yet called 3D printing or AM at the time. In 1990,
various processes for making a three-dimensional object of the plastic extrusion technology most widely associated with
almost any shape from a 3D model or other electronic data the term “3D printing” was commercialized by Stratasys
source primarily through additive processes in which under the name fused deposition modelling (FDM). In 1995,
successive layers of material are laid down under computer Z Corporation commercialized an MIT-developed additive
control. A 3D printer is a type of industrial robot. Early AM process under the trademark 3D printing (3DP), referring at
equipment and materials were developed in the 1980s. In that time to a proprietary process inkjet deposition of liquid
1984, Chuck Hull of 3D Systems Corp, invented a process binder on powder. AM technologies found applications
known as stereo lithography employing UV lasers to cure starting in the 1980s in product development, data
photopolymers. Hull also developed the STL file format visualization, rapid prototyping, and specialized
widely accepted by 3D printing software, as well as the manufacturing. Their expansion into production (job
digital slicing and infill strategies common to many production, mass production, and distributed
processes today. Also, during the 1980s, the metal sintering manufacturing) has been under development in the decades
forms of AM were being developed (such as selective laser since. Industrial production roles within the metalworking
sintering and direct metal laser sintering), although they industries achieved significant scale for the first time in the

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
early 2010s. Since the start of the 21st century there has incorporating major aspects to be considered for businesses
been a large growth in the sales of AM machines, and their before pursuing 3D printing has been developed that will
price has dropped substantially. According to Wohlers need to be verified through case study/ field research in
Associates, a consultancy, the market for 3D printers and industry. It is further expected that businesses will benefit
services was worth $2.2 billion worldwide in 2012, up 29% from the model through informed and improved decision
from 2011. Applications are many, including architecture, making prior to deploying such cutting-edge technology on
construction (AEC), industrial design, automotive, aerospace, their production line.[3]
military, engineering, dental and medical industries, biotech
(human tissue replacement), fashion, footwear, jewellery, AlexandruPirjan Dana-Mihaela Petroşanu in his journal
eyewear, education, geographic information systems, food, “The impact of 3D Printing technology on the society and
and many other fields.[1] economy” concluded in this paper, we have presented and
analysed the impact of 3D printing technology on the society
Additive manufacturing is the official industry standard term and economy. After presenting, in the introduction, a brief
for all applications of the technology. It is defined as the history of 3D printing, in the second section we have
process of joining materials to make objects from 3D model depicted the additive technology and the materials used in
data, usually layer upon layer, as opposed to subtractive rapid prototyping. In the third section, we have highlighted
manufacturing methodologies. Synonyms are additive the main advantages and limitations of the 3D printing
fabrication, additive processes, additive techniques, additive technology, while in the fourth section we have made a
layer manufacturing, layer manufacturing, and freeform survey of the most significant existing 3D printing solutions.
fabrication. The primary applications of additive fabrication We have compared these 3D printing solutions, taking into
are design/modeling, fit and function prototyping, and direct account their technical specifications and prices. One can
part production. Around the world, AM is changing the way conclude that the 3-D printing technology’s importance and
organizations design and manufacture products. When used social impact increase gradually day after day and
correctly, it can save impressive amounts of time and money. significantly influence the human’s life, the economy and
Companies maintain that AM has helped trim weeks, even modern society.[4]
months, of design, prototyping, and manufacturing time,
while avoiding costly errors and enhancing product Vinod G. Gokhare and et.al in his paper titled “A Review
quality.[2] paper on 3D-Printing Aspects and Various Processes Used in
the 3D-Printing” conclude that Introduction part is about the
II. LITERATURE SURVEY brief history of 3D printing, in the next section we have
Brogan Rylands and et.al in his paper “3D Printing - To depicted the 3D-printing and the processes used in 3D-
print or not to print? Aspects to consider before adoption - A printing and the properties of the 3Dprinter materials. In the
supply chain perspective” has concluded that There is much third section, we have highlighted the main advantages and
complexity around 3D printing, which brings about the need limitations of the 3D printing technology. One can conclude
to essentially reengineer value streams. It is a collaborative that the 3-D printing technology's importance and social
attempt across the whole organisation and there are many impact increase gradually day by day and influence the
aspects to be considered, stemming not only from a business human's life, the economy, and modern society. 3D Printing
and technical perspective but also social and environmental technology could revolutionize the world. Advances in 3D
aspects that require consideration. printing technology can significantly change and improve the
way we manufacture products and produce goods
This paper provided an overview of what 3D printing is, worldwide. An object is scanned or designed with Computer
examples of industries that it is currently deployed in, how it Aided Design software, then sliced up into thin layers, which
can influence supply chains and aspects for consideration can then be printed out to form a solid three-dimensional
before adoption. It highlighted the need for increased product. As shown, 3D printing can have an application in
awareness and collaboration in the area and future almost all of the categories of human needs as described by
challenges and opportunities. Maslow. While it may not fill an empty unloved heart, it will
provide companies and individuals fast and easy
However, how does a company prepare for such a change? manufacturing in any size or scale limited only by their
How does it educate itself? How can the fire for 3D printing imagination. 3D printing, on the other hand, can enable fast,
be sparked in industry? When is the right time to adopt 3D reliable, and repeatable means of producing tailor-made
printing? What additional aspects are managers currently products which can still be made inexpensively due to
considering when facing the 3D adoption challenge? Are all automation of processes and distribution of manufacturing
aspects of equally important or can even some aspects be needs.[5]
disregarded? How has 3D printing impacted on
manufacturing and the wider supply chain today? How will Thabiso Peter Mpofu and et.al from his journal paper titled
3D printing impact manufacturing and the wider supply “The Impact and Application of 3D Printing Technology”
chain in future? How well is Australia positioned when concluded that the 3D printing industry is set on a growth
compared to their international counterparts in regards to trajectory as evidenced by the growth forecasts. The
3D printing? How does 3D supply chain costing compare applications of 3D printing are increasing as more and more
with traditional manufacturing supply chain costing? How research is carried out. 3D printing will change the way
mature does your supply chain need to be in order to deploy people acquire products as evidenced by the Amazon
3D technology meaningfully and harvest its benefits? proposed model. The field is definitely a game changer with
lots of prospects to look out for.[6]
It is expected that this research will contribute to academia/
theory and practice. A conceptual model or framework

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
Baljinder Singh Shahi in his paper titled “Advanced review work includes study of design and analysis of
Manufacturing Techniques (3D Printing)” concluded that sprocket chain. Also study the various optimization
Additive manufacturing, starting with today's infancy period, techniques. For the finite element-based optimization
requires manufacturing firms to be flexible, ever-improving purpose the study of suitable software for optimization of
users of all available technologies to remain competitive. weight and selection of alternate material will carry out by
Advocates of additive manufacturing also predict that this referring different books and earlier research works
arc of technological development will counter globalization, published in reputed journals.[10]
as end users will do much of their own manufacturing rather
than engage in trade to buy products from other people and Suthar Nirav and et.al in his journal entitled “Proposed
corporations. The real integration of the new additive Work on Sprocket Side Stand Retrieve Mechanism in Two-
technologies into commercial production, however, is more a wheeler Vehicle” concluded that “Sprocket- side stand
matter of complementing traditional subtractive methods retrieve mechanism for two-wheeler vehicle” will definitely
rather than displacing them entirely.[7] good retrieve system. This mechanism is not requiring to any
extra fuel or alternative and direct current. It works with
Avishek Mishra and et.al in his journal paper titled directly by the chain drive. The chain drive gets power from
“Literature Survey of Convertible Wheel Drives Using Chain the engine. So manufacturing and maintenance cost is
Sprocket” concluded that chain sprocket engagement used to economical. Since the setup is compact it does not affect the
drives the wheel, this discussion suggests the selection of performance of the vehicle. This system can be implemented
various chain arrangement used for different types of in all types of bikes by changing small variation in size and
vehicle. It shows the various advantages like transmits more cost of this system also very low and so it will not affect the
power than belts. No slip takes place during chain drive. economic level also. While compare to other system this will
Production cost is relatively high and the chain drive has be the life saver.[11]
velocity fluctuations especially when unduly stretched. It has
the ability to transmit motion to several shafts by one chain III. METHODOLOGY
only. The chain drive needs accurate mounting and careful
maintenance, particularly lubrication and slack adjustment.
It gives high transmission efficiency (upto98percent). It can
be operated under adverse temperature and atmospheric
conditions. It permits high speed ratio of 8 to 10 in one
step.[8]

Abhishek Baruaand Sasmita Kar in their journal titled

“Review on Design Optimization of Sprocket Wheel Using
Different Techniques” concluded that it is interesting to
observe that mostly researchers have chosen Finite Element
Analysis to optimize the sprocket. Mostly they have chosen
different grades of steel as their base material. Few have
tried to substitute the steel with composite material also. As
compared to steel, composites are not so easy to be
There are some procedures for printing. First you must
machined using traditional machining processes. Few of the
create a computer model for printing the object. For creating
researchers have optimized the sprocket using FEA software
that, you can use Computer Aided Design Software like
without performing the experiment validation. Hence, it can
AutoCAD, 3DS Max etc. After the object file is created, the file
be concluded that more weight reduction can be achieved by
needs to be modified. The object file contains numerous
re-designing the sprocket geometry like teeth profile, hub,
amounts of curves. Curves cannot be printed by the printer
bolt holes, pockets etc. and more torque can be achieved.
directly. The curves have to be converted to STL (Stereo
Since metals will be going to deplete someday, researchers
lithography) file format. The STL file format conversion
are searching for more alternative materials. Polymer
removes all the curves and it is replaced with linear shapes.
composites are slowly finding its place as a replacement to
Then the file needs to be sliced into layer by layer. The layer
steel. Re-designing of sprocket can be done by using the
thickness is so chosen to meet the resolution of the 3D
different compositions of polymer matrix composites and
printer we are using. If you are unable to draw objects in
more weight can be optimized without reducing the power
CAD software, there are many websites available which are
transmission. Metal-Matrix composite can be also used as a
hosted by the 3D printing companies to ease the creation of
substitute to steel for manufacturing of sprocket. Cost of
3D object. The sliced file is processed and generates the
material is an another factor which restricts the use of
special coordinates. These coordinates can be processed by a
alternate materials in place of existing materials for sprocket
controller to generate required signal to the motor for
manufacturing for automobiles and machineries. New
driving extruder. This layer by layer process generate a
manufacturing techniques can also be introduced or the
complete object.
existing methods can also be optimized for fast and precision
manufacturing of the sprockets. So the above techniques can
IV. DESIGN
be used for further development of chain sprocket and more
Computer-aided design (CAD) is the use of computer
efficiency can be achieved during power transmission.[9]
systems to assist in the creation, modification, analysis, or
optimization of a design. CAD software is used to increase
Nikhil P. Ambole, Prof. P. R. Kale in their journal paper “A
the productivity of the designer, improve the quality of
Review on Carbon Fiber Sprocket Design Analysis and
design, improve communications through documentation,
Experimental Validation” concluded that This literature
and to create a database for manufacturing. CAD output is

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
often in the form of electronic files for print, machining, or
Using pocket command, cut through the previously
other manufacturing operations. revolved surface to form one part of the tooth
profile.
CAD software for mechanical design uses either vector-based
graphics to depict the objects of traditional drafting, or may
also produce raster graphics showing the overall appearance
of designed objects. However, it involves more than just
shapes. As in the manual drafting of technical and
engineering drawings, the output of CAD must convey
information, such as materials, processes, dimensions, and
tolerances, according to application- specific conventions.

The sprocket that is to be printed in this project is designed

in one of the popular CAD software, CATIA.

The sprocket is designed in Catia in the following way: Fig.4. Catia (pocket command)

In Catia, part modelling is to be selected first. Then,
by selecting one of the three planes, the following 2-
Select circular pattern and specify the angular
d sketch is drawn using appropriate measurements. spacing of each tooth of the gear and the total
number of teeth on the profile.

Fig.1. Catia (sketch 1) Fig.5. Catia (circular pattern command)

Using the revolve or shaft command, revolve the
A groove in the hub of the sprocket can be made
selected sketch through 360° about the central axis. similarly by using pocket command and removing
the material with reference to the sketch drawn on
the surface of the part body.

Fig.2. Catia (revolve/shaft command)

Now select one of the faces and select sketch option. Fig.6. Catia (pocket command)
Draw the 2-dimensional tooth profile of the gear
teeth.
Choose and apply the material to the part body if
needed and save the part body in the desired folder.

Fig.3. Catia (sketch 2)

Fig.7. Catia (material selection)

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The sprocket that is to be 3-d printed is designed and saved
in the computer and it has to be modified further to print it
in a 3-d printer

Fig.11. Saving part file

Now select ‘.stl’ from the list of options to save the

file.

Fig.8. Sprocket 3-D model

Conversion to STL File Format

The object (sprocket, in this case) can be converted to STL
format file by the following procedure:

Open the previously saved design file in the CAD
software (CATIA, in this case) and find ‘File’ on the
menu

Fig.12. Selecting STL format

Save the file in the respective folder.

Fig.9. Catia (file menu)

Click on the ‘File’ menu and select ‘Save as’ as

shown in the figure below.

Fig.13. saving .stl file

The 3d printer should be connected to the pc or the laptop,

on which you have been working and the software like CURA
from Ultimaker or Ideamaker has to be pre-installed on the
computer.

V. RESULTS
The sprocket is manufactured with the PLA material by
Fused Deposition Modelling using 3D-printing machine.

Fig.10. Catia (save as) VI. CONCLUSION

In this project modelling of SPROCKET is carried out with

After selecting ‘Save as’, the following window CATIA V5R20 software by using various commands. After
appears. creating model we save the component in ‘.stl’ file. Import
the component into the 3D Printing machine by using cura

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
software, by using FDM (Fused Deposition Modelling) [6] Thabijo Peter Mpofu, The impact and application of 3D
method with PLA material (Poly Lactic Acid). And then we Printing technology, Volume 3, issue 6 in June 2014,
get the component. Design and 3D Printing of sprocket is ISSN 2319- 7064
done.
[7] Baljinder Singh Shahi, Advanced Manufacturing
Techniques(3D Printing), volume 4, issue 4 in 2016,
REFERENCES
ISSN 2320-2092
[1] https://www.economist.com/technology-
quarterly/2013/09/05/3d-printing-scales-up [8] Avishek Mishra, Literature Survey of Convertible
Wheel Drives Using Chain Sprocket, volume 2, issue 2
[2] https://wohlerassociates.com/additive
in 2016, ISSN 2395-4396
manufacturing.html
[9] Abhishek Barua, Review on Design Optimization of
[3] Brogan Rylands, 3D Printing - To print or not to print?
Sprocket Wheel Using Different Techniques, volume 8,
Aspects to consider before adoption - A supply chain
issue 1 in 2018, ISSN 2250-3234
perspective in the year 2015.
[10] Nikhil P. Ambole, A Review on Carbon Fiber Sprocket
[4] ALEXANDER Pirjan and Dane-Mihaela Petrosanu, The
Design Analysis and Experimental Validation, volume
impact of 3D Printing technology n the society and
2, issue 7 in July 2016, ISSN 2395-1052
economy
[11] Suthar Nirav, Proposed Work on Sprocket Side Stand
[5] Vinod G. Gokhare, A review paper on 3D Printing
Retrieve Mechanism in Two Wheeler Vehicle, volume 5,
aspects and various processes used in 3D-Printing,
issue 6 in 2017, ISSN 2321-0613
volume 6, issue 6 in June 2017, ISSN 2278-0181

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