This thesis investigates the geometric analysis of spline shafts by employing several different methods of analysis, including contact and non-contact methods. An extensive experiment was carried out by employing the contact method of surface analysis or surface roughness analysis by means of a surface roughness profilometer. The purpose of this experiment was to investigate a wide range of factors that are associated with behaviors, including fretting damage, manufacturing precision, and wearing potential. Based on the findings, it was discovered that a number of roughness factors had the ability to offer meaningful insights on possible phenomena. Three-dimensional scanning, which is a non contact method that makes use of modern technology, was also utilized in order to find deviations on the surface between the standard computer-aided design (CAD) model and the shafts that were manufactured using a high precision 3D scanner. I have also developed a manufacturing technique for spline shafts that has the potential to be the best possible one through calculation. This technology fits the criteria of the industrial sector and enables machining that is both fast and efficient.