Abstract
This paper presents an extended comparative analysis of the traditional injection molding technology and additive 3D printing technology in the production of polymer rollers for belt conveyors of various applications. The technological features of the processes, their production limitations, economic feasibility, and areas of rational application in mass and small-batch manufacturing are considered. The mass and dimensional characteristics of the rollers were calculated, and the reduction in metal consumption compared with conventional steel analogues was evaluated. The influence of reducing the mass of rotating components on the dynamic parameters of the system, including starting loads, operating modes, and overall energy consumption of the conveyor line, was analyzed. It is shown that the use of modern polymer materials allows reducing the roller mass by more than two times without deterioration of operational characteristics. This contributes to improved energy efficiency, reduced wear of drive units, and increased service life of the equipment. Criteria for selecting the manufacturing technology depending on production volume, strength requirements, and operating conditions are determined.