In any gearbox, gears play a crucial role in motion transmission and contribute considerable weight to the gearbox. Usually, gears fail when the operating stress exceeds the maximum permissible stress. The power transmitted by the gears is directly proportional to these stresses. This paper intends a systematic study of gear blank hub, web, and rim geometry along with rim angle and fillets to reduce the weight of helical gear without altering the material and tooth geometry with the proper balance between weight reduction and total deformation. In turn, the total deformation in optimized gear will be in the safety range, 30% of existing gear deformation. Also aims to determine the magnitude of total deformation and Von-Mises stresses for a particular configuration of helical gears that transfer power while maintaining functionality and lowering the gear's material cost and energy consumption. Incorporating change in dimensional features of gear blank for weight reduction over the existing design and evaluation of individual feature behavior trends could be considered as the key parameters for assessment for this work.