Ball bearings are reliable and efficient in many applications due to conventional manufacturing methods. However, additive manufacturing, particularly 3D printing, modified the production process by enabling design customization, material optimization, and rapid prototyping. This study uses an analytical and numerical technique to investigate the effects of radial deformation and contact stress on the SKF 6308 ball bearing. Analytical analysis uses Hertzian contact theory, while numerical analysis uses ANSYS Workbench. The study compares the structural characteristics of conventional and 3D-printed ball bearings. Results indicate that the conventional bearing has a maximum radial deformation of 0.0521653 mm, while 3D-printed bearing has 0.16567 mm. Similarly, the corresponding contact stresses are 1402.6 MPa and 1731.3 MPa, with an analytical result of 1567.03 MPa. The study also includes a thermal analysis of significant differences in contact stress between conventional, 3D-printed, composite bearings made from Al7075 + 10% SiC and Al7075 + 9% B4C. These materials have contact stresses of 1673.2 MPa, 2131.1 MPa, 950.82 MPa, and 1055.20 MPa. Due to their enhanced mechanical properties, composite bearings exhibited minimum contact stresses and excellent thermal performance and durability. These results illustrate the significance of material selection and manufacturing processes in optimizing high-stress and high-temperature bearing performance.