Simulating bodies comprised of hybrid and porous materials regarding their mechanical properties is challenging, as it is possible to combine materials of widely varying material properties. These hybrid structures combine a steel surface layer with a porous metal foam core, offering an optimal balance of strength, durability, and reduced weight [1]. Manufacturing is carried out through additive manufacturing techniques, allowing for a wide variety of material combinations [2]. Currently, the primary materials under investigation include two types of steel—17-4 PH and 316L—as well as AlSi10Mg, an aluminium alloy. A major application of these materials lies in the production of spur gears as they are used in highly loaded applications. To understand the performance characteristics of such gears, a specialized finite element method (FEM) simulation framework was developed. This framework is an extension of an existing simulation model for fibre-reinforced plastic gears, which considers variations in material properties based on fibre orientation [3]. The adaptation of this framework enables the input of various hybrid material combinations and allows for gradations between materials to be incorporated. One of the framework’s standout features is its ability to automatically generate different gear geometries. Beyond essential parameters like module and number of teeth, the system allows modifications such as adjustments to tooth root and tip retractions. By leveraging this simulation tool, studies on factors such as surface layer thickness and the effects of different material pairings were conducted. This work enhances the understanding of hybrid, porous materials and their impact on gear performance. Additionally, the data obtained will be used to refine and extend the ISO 6336 standard [4] in future work, providing an analytical basis for designing gears with these materials. Acknowledgement Funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) – Project-ID 511263698 – TRR 375