What module should I use for 3D printed gears?

For FDM printing with a 0.4mm nozzle, use module 1.0 or larger. Module 1.5-2.0 gives robust teeth that print well. Smaller modules (0.5-0.8) require a fine nozzle or resin printing for adequate tooth definition.

How do I ensure two gears mesh properly?

Both gears must have the same module and pressure angle. The centre distance = (teeth1 + teeth2) x module / 2. Add 0.1-0.2mm clearance to the centre distance for smooth operation of 3D printed gears.

What pressure angle should I use?

Standard pressure angle is 20 degrees, which works well for 3D printing. 14.5 degrees gives quieter operation but weaker teeth. Do not mix pressure angles between meshing gears.

How wide should gear teeth be?

Face width should be 5-10x the module for adequate strength. For 3D printed gears, err towards wider (8-10x module) to compensate for the lower strength of printed material compared to metal.

3DPrintCalcs

Gear Calculator — Spur Gear Dimensions

Design spur gears with correct module, tooth count and pitch circle dimensions.

Module

Tooth size factor

Number of Teeth

Pressure Angle

Face Width

Backlash Clearance

How We Calculate This

Spur Gear Formulas

Pitch diameter = Module x Number of teeth
Outer diameter = Pitch diameter + 2 x Module
Root diameter = Pitch diameter - 2.5 x Module
Circular pitch = Pi x Module
Base circle = Pitch diameter x cos(Pressure angle)

The module determines the size of the teeth. For two gears to mesh, they must share the same module and pressure angle. The pitch circle is where the teeth of meshing gears make contact.

Frequently Asked Questions

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Last updated: February 2026

All calculations are estimates. Always verify settings with test prints before committing to final prints.