High-Performance Composite Gears: A Systematic Review of Materials, Processing, and Performance

Composite gears have emerged as game-changing mechanical components across various engineering fields due to their multifunctional physical properties, such as low density, thermal resistance, and mechanical robustness. Although traditional metallic gears are well established and reliable, their efficiency is limited in certain applications. In contrast, composite gears reinforced with carbon, glass, or polymer fibers offer superior strength-to-weight ratios, enhanced corrosion and wear resistance, and improved vibration damping characteristics. The studies demonstrate that hybrid and fiber-reinforced composite gears can achieve weight reductions of 20–50% compared with steel gears, while maintaining comparable stiffness and load-carrying capability. Polymer and reinforced composite gear systems show operating temperature reductions of up to 40% due to improved tribological behavior and thermal dissipation. In metal–matrix composite systems, compressive strength improvements up to around 60% have been reported. Additionally, composite architectures provide improved fatigue life, reduced transmission error, and enhanced vibration damping. Developments in gear design, composite materials, and their integration into composite gear systems were identified through a structured literature survey using Scopus and Google Scholar, systematically compiling manufacturing methods, material performance characteristics, and applications. Targeted keywords related to gears, composites, additive and hybrid manufacturing, lightweight design, and power transmission yielded 132 relevant publications, which were subsequently refined through screening and cross-referencing, with the final section focusing specifically on composite gear applications. The review highlights key opportunities, current challenges, and potential future directions for the development of high-performance composite gear systems.