Additive manufacturing is a technology rapidly expanding on a number of industrial sectors. However, it is still hampered by low productivity, poor quality and uncertainty of final part mechanical properties. Materials for production of given components are composite materials, especially on the basis of so-termed CFRP, CRP, (carbon fibre - so-termed polymers reinforced by carbon fibres).  Composite fibers have properties that can add high strength and stiffness to the printed part. Like all manufacturing processes, composite printing is only suitable for certain design applications. The fibers have a predetermined width during printing and, due to geometrical limitations, can only be used to reinforce structures meeting a certain minimum thickness.

Gear is one of the most important machine elements in mechanical power transmission system. It is a rotating machine part having cut tooth which meshes with another tooth part in order to transmit torque. Theoretical designing of spur gear is done as per Lewis equation and 3D modelling is done using ANSYS ACP software.

The objective of this paper is to predict the deformation length of carbon/onyx spur gear using Finite Element Analysis (FEA) results through the torque load.  Finite Element analysis software ANSYS Workbench 19.0 is used to study the load carrying capacity of spur gear. A shell model has been established for simulation of the spur gear which enables to understand the mechanical strength and strain at failure of the composite materials.