Input Gear (Z₁)
Teeth80
Pitch ⌀240.0 mm
Addendum ⌀246.0 mm
Dedendum ⌀232.5 mm
Base ⌀225.5 mm
Output Gear (Z₂)
Teeth20
Pitch ⌀60.0 mm
Addendum ⌀66.0 mm
Dedendum ⌀52.5 mm
Base ⌀56.4 mm
Performance
Gear Ratio4.000 : 1
Output RPM240
Input Torque795.8 Nm
Output Torque194.1 Nm
Efficiency97.5%
Transverse Module3.000 mm
Center Distance150.0 mm
Multi-Stage Gearbox Designer
Configure up to 4 stages. System auto-calculates cumulative ratio, efficiency, and torque at each stage.
System Summary
Actual Total Ratio—
System Efficiency—
Final Output RPM—
Final Output Torque—
Manufacturing Pipeline
3D Print
PLA Pattern
Shell Build
Ceramic
Burnout
8hr Cycle
Metal Pour
1600°C
Machine
CNC
Heat Treat
Carburize
Casting Calculator
Gear Volume—
Steel Mass—
Pattern Mass (PLA)—
Metal Needed (+30%)—
Pattern ⌀ (+shrinkage)—
Melt Temperature—
3D Print Estimate
PLA Filament—
Print Time (est.)—
Layer Height0.12 mm
Infill100% Solid
Perimeters4 walls
Speed40 mm/s
Heat Treatment Schedule
Pack carburizing — sealed box with charcoal + BaCO₃ + CaCO₃
Case Depth1.0 mm
Surface Hardness58–62 HRC
Core Hardness30–38 HRC
Total Cycle~12 hours
Burnout Cycle (Lost-PLA)
0–3.5hr
→350°C
→350°C
3.5–4.5hr
Hold 350°C
Hold 350°C
4.5–6hr
→600°C
→600°C
6–7hr
Hold 600°C
Hold 600°C
7–8.5hr
→900°C
→900°C
Code Generator
Generate parametric code for OpenSCAD, FreeCAD, and JSCAD. Copy and run in free tools.
// Click a generator button above to create code
// Generated code runs in free, open-source tools:
//
// OpenSCAD → openscad.org (download, paste, render)
// FreeCAD → freecad.org (run as Python macro)
// JSCAD → openjscad.xyz (paste in browser, instant 3D)
CLI Quick Reference
# Render STL from OpenSCAD
openscad -o gear_output.stl gear_input.scad
# FreeCAD headless macro
freecad -c generate_gear.py
# Slice STL to G-code
prusa-slicer --load casting.ini -o gear.gcode gear.stl
Engineering Drawings
Annotated technical drawings with GD&T tolerances. Export as SVG for print or CNC.
GD&T Tolerances
Bore (H7)⌀25 +0.021 / 0
Keyway±0.05 mm
End Face Flatness0.05 mm
Tooth Runout0.03 mm (AGMA 8)
Surface Finish (Flanks)Ra 1.6 μm
Cost Estimator
Per-gear cost breakdown using JUGAAR lost-PLA casting pipeline. Pakistan market prices.
Input Gear Cost
3D Printing (PLA)—
Ceramic Shell—
Burnout Kiln—
Alloy Steel—
Melting/Pour—
CNC Machining—
Heat Treatment—
SUBTOTAL—
Output Gear Cost
3D Printing (PLA)—
Ceramic Shell—
Burnout Kiln—
Alloy Steel—
Melting/Pour—
CNC Machining—
Heat Treatment—
SUBTOTAL—
Total Pair Cost
Gear Pair (PKR)—
Gear Pair (USD)—
Import Equivalent—
JUGAAR Savings—