Abstract: Nylon 6 and Glass fibre is a thermoplastic polymer widely recognized for its excellent impact resistance, toughness, and dimensional stability. However, its relatively moderate mechanical strength and thermal resistance limit its application in highperformance systems such as polymer composite gears. This study explores the potential of as a base material for gear manufacturing, focusing on improving its properties through reinforcement with materials like glass fibers, carbon fibers, PTFE, graphite, and nano-fillers. These reinforcements aim to address the stringent requirements of gears, including high wear resistance, low friction, and durability under operational loads. The investigation adopts a multi-faceted approach, including experimental testing and computational simulations. Mechanical testing, such as tensile strength, fatigue life, and impact resistance, evaluates the material's structural integrity, while thermal testing measures heat deflection temperature and thermal expansion properties. Tribological analysis assesses wear rate and friction behavior under operational conditions. Additionally, Finite Element Analysis (FEA) simulations provide insights into stress distribution, thermal effects, and dynamic performance, complementing experimental findings.

Results from these analyses are benchmarked against traditional gear materials like Nylon and POM to identify composites' strengths and weaknesses. The incorporation of fillers significantly improves the mechanical and thermal properties of making it a strong candidate for light- and medium-duty gear applications. The study also evaluates the cost-effectiveness of -based composites, highlighting their potential to provide a balanced solution between performance and economic feasibility. This research demonstrates the viability of composites for use in lightweight, highperformance gears, particularly in cost-sensitive markets. By optimizing the formulation of composites, the study contributes to advancing gear material technology and offers a sustainable alternative to conventional materials. These findings pave the way for further exploration of polymer composites in advanced engineering applications.

| DOI: 10.17148/IARJSET.2025.12339