Direct Gear Design^® works ideally for plastic gears because it provides total design flexibility that is not achievable using the traditional gear design that developed for machined gears. Several design issues need to be considered when designing a plastic gear. Direct Gear Design compensates plastics' low strength and low thermal conductivity by balancing pinion and gear tooth bending stresses, reducing the bending stress concentration, minimizing and balancing specific sliding velocities resulting in maximum efficiency and minimum heat generation.

A big roadblock to producing a precise plastic gear is the distortion from shrinkage during the injection molding process. This distortion results in an inconsistent gear tooth profile and a low gear accuracy. The Genetic Molding Solution^® cavity correction method was developed for producing the high precision molded gears.

Today, to get a high precision part, molders go through number of tool cavity corrections until they get it right.

The shape of a molded part is the result of a combination of factors including the tool geometry, material properties, molding process parameter, etc. These factors are the genetic molding blueprint of a part, much like DNA is the genetic blueprint of living organism.

Genetic Molding Solution^® technology is based on the mathematical prediction software, which defines the transformation function between initial cavity profile and the resulting part profile. Than the inverted transformation function is applied to desired (ideal) part profile to define the final mold cavity profile. This method does not depend on plastic material properties, part shape, or molding process parameters. This technology allows to go from initial tooling cavity to final tooling cavity in one straight process. Genetic Molding Solution^® software was created by Dr. Yuriy V. Shekhtman (y.shekhtman@gmail.com).

Genetic Molding Solution method delivers:

• Corrected tool cavity geometry for the high precision plastic parts
• Eliminate the expense of repetitive cavity correction
• Cuts process development and delivery time
• Increase precision of molded parts

Typical results achieved with the Genetic Molding Solution^® are shown in the roll test char below. The cam gear is not particular molding friendly part containing the metal shaft, two cams, and six spokes. It required to be the AGMA class Q8. Traditional redundancy based cavity correction method just did not work. With Genetic Molding Solution^® became possible to go from a class Q5 gear to a class Q9 in one straight process.