A hybrid composite lamination and laser-cutting process for high-precision, low-cost prototyping of functional non-circular gears

This study proposes a materials-by-design approach to develop a laminated composite from alternating layers of flexible polyvinyl chloride and a cellulose-based adhesive, aiming to produce functional, high-precision planar components. The polymer–matrix composite was engineered to overcome key limitations of additive manufacturing, such as poor interlayer adhesion and low-dimensional accuracy. This novel material was compressed into 5 mm blocks and laser-cut to fabricate a pair of functional square gears. Tensile testing revealed a fourfold increase in tensile strength equal to 44.05 MPa for samples loaded parallel to the build direction compared to raw polyvinyl chloride. Quantitative T-peel tests confirmed strong bonding, with a steady-state force of 8–11 N and a calculated energy release rate of 760 J/m 2 , ensuring structural integrity and resistance to delamination. Functional testing of the manufactured gears confirmed smooth mating through 360° rotation, achieving a dimensional accuracy of 0.01 mm and a gear tooth flank surface roughness of 5.36 µm. The results demonstrate that this laminated composite offers superior in-plane mechanical properties, making it a promising candidate for planar mechanisms. The methodology is further validated as a high-precision, cost-effective, and rapid alternative to additive manufacturing, suggesting a significant potential for use in engineering education and functional prototyping.