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Abstract: In this report a detailed study on the design and analysis of SPUR GEAR with the Additive manufacturing technique Laser Powder Bed Fusion. The variety of materials for the additive manufacturing are discussed and the compatible material ALSI was selected for GEAR It also focuses on the various simulations of manufacturing the Piston part by utilizing “AUTODESK NETFABB SIMULATION 2020.1” and analysis was also done in ANSYS for the comparison of conventional material with ALI10MG . The residual stresses, von mises stress, hotspots and lack of fusion spots from simulation results are discussed and the suitable heat treatment analysis is studied for relieving the stresses. The strength evolution of the as- built ALSI part by LPBF and total deformation, equivalent stress, principal elastic strain are also plotted from ansys and the further heat treated parts under different conditions are studied and the best suitable heat treatment method for the manufacturing of ALSI part by LPBF was concluded which could be beneficial for the manufacturing of the actual part of the gear in automobile industries.