This paper presents experimental findings on the surface durability of 3D-printed polymer gears, focusing on their ability to function without lubrication. The study investigates factors influencing wear in non-lubricated gear contact, including sliding speed, material hardness, surface finish, geometry, and microstructure. Four materials—PA, PLA, ABS, and PP—were tested using a mechatronic setup with adjustable shafts, loading systems, and a control unit. Wear was evaluated using a double-flank gear inspection machine (Frenco ZWP 06) and a 3D scanner (ATOS CORE 135). PA and PP gears failed structural integrity tests, while PLA showed superior resistance to abrasive wear compared to ABS. ABS gears had better structural integrity but lower wear resistance. The study highlights the impact of printing parameters, such as layer thickness and temperature, on gear performance. For FDM, lower layer thickness improved mechanical and tribological performance, while higher layer thickness increased strength. Printing temperature significantly influenced wear resistance, with optimal values between 210–220°C for PLA and 240°C for ABS. The results indicate that PLA gears exhibited the best wear resistance, with minimal changes in radial deviation. ABS gears showed more pronounced wear, though their structural performance was better. The study emphasizes the need for standardized testing and guidelines for 3D-printed gears, as current research is still in its early stages. The findings contribute to understanding the performance of 3D-printed gears in mechatronic systems and highlight the importance of material selection and printing parameters in achieving durability.This paper presents experimental findings on the surface durability of 3D-printed polymer gears, focusing on their ability to function without lubrication. The study investigates factors influencing wear in non-lubricated gear contact, including sliding speed, material hardness, surface finish, geometry, and microstructure. Four materials—PA, PLA, ABS, and PP—were tested using a mechatronic setup with adjustable shafts, loading systems, and a control unit. Wear was evaluated using a double-flank gear inspection machine (Frenco ZWP 06) and a 3D scanner (ATOS CORE 135). PA and PP gears failed structural integrity tests, while PLA showed superior resistance to abrasive wear compared to ABS. ABS gears had better structural integrity but lower wear resistance. The study highlights the impact of printing parameters, such as layer thickness and temperature, on gear performance. For FDM, lower layer thickness improved mechanical and tribological performance, while higher layer thickness increased strength. Printing temperature significantly influenced wear resistance, with optimal values between 210–220°C for PLA and 240°C for ABS. The results indicate that PLA gears exhibited the best wear resistance, with minimal changes in radial deviation. ABS gears showed more pronounced wear, though their structural performance was better. The study emphasizes the need for standardized testing and guidelines for 3D-printed gears, as current research is still in its early stages. The findings contribute to understanding the performance of 3D-printed gears in mechatronic systems and highlight the importance of material selection and printing parameters in achieving durability.