Additive manufacturing of a passive, sensor-monitored 16MnCr5 steel gear incorporating a wireless signal transmission system

The combination of functions in a single component, efficient use of limited space, comprehensive acquisition of process and sensor data and development of passive, wireless monitoring systems are all at the focus of current research. Additive manufacturing is playing an increasingly important role in these developments, because it acts as an enabler for free-form structures, allows access to the interior of the component through its layer-by-layer build-up, and facilitates the processing of a wide variety of materials. Within this work, the aspects mentioned are jointly addressed by the development of a monitored additively manufactured gear (material: 16MnCr5) that communicates wirelessly. This paper shows how an RFID-antenna can be optimized by simulation, incorporated in the design of a metallic gear, then built up in a single manufacturing process and linked to an in-situ inserted sensor board. The approach is validated by fabrication of a sensor-monitored prototype and verified in respect of its functionality and internal structure.