Precision CNC Machined Gears & Sprockets

AGMA quality grades range from 3 (lowest precision) to 15 (highest precision). AGMA 8-9 is suitable for general industrial applications with moderate speeds and loads. AGMA 10-11 is recommended for high-speed applications, reduced noise requirements, or higher precision needs. AGMA 12+ is reserved for aerospace, robotics, and ultra-precision applications requiring ground tooth finishes. We can help you select the appropriate quality grade based on your speed, load, noise, and accuracy requirements.

Yes, we manufacture gears to customer specifications including custom tooth profiles, non-standard pitches, and special modifications. Provide us with your drawing showing module/pitch, number of teeth, pressure angle, face width, and any special requirements (helix angle, tooth modifications, hub dimensions). We can also reverse-engineer existing gears or work with you to design optimal gears for your application.

Helical gears offer several advantages: smoother, quieter operation due to gradual tooth engagement; higher load capacity from increased contact ratio; reduced vibration at higher speeds. However, helical gears generate axial thrust loads requiring thrust bearings, and are slightly more expensive to manufacture. Spur gears are simpler, more economical, and sufficient for many applications. We can help you evaluate the trade-offs based on your speed, load, noise, and cost requirements.

Yes, we provide complete heat treatment services including case hardening (carburizing), through hardening, induction hardening, and nitriding. Case hardening is most common for gears, providing a hard wear-resistant surface (HRC 58-62) with a tough ductile core. For high-precision gears, we grind the teeth after heat treatment to correct any distortion and achieve AGMA 12+ quality. Heat treatment selection depends on your material, load requirements, and quality grade.

Yes, we can reverse-engineer replacement gears by measuring existing components. Provide us with the mating gear or gearbox, and we'll measure the module/pitch, tooth count, pressure angle, and other critical dimensions. We can then manufacture exact replacements or improved designs. For worn gears, we can determine the original specifications and manufacture new gears to proper dimensions. Matched gear sets are available with verified tooth contact patterns.

Lead times vary based on complexity, quantity, and material. Standard spur/helical gears from stock materials typically take 3-4 weeks including hobbing and any required heat treatment. Precision ground gears require an additional 1-2 weeks for post-heat-treat grinding. Bevel gears, worm gears, or custom profiles may take 4-6 weeks due to specialized tooling. High-volume production orders are quoted based on quantity. Rush services available for urgent requirements.

We verify tooth contact using Prussian blue compound applied to gear teeth, then rolling the gears under light load to transfer the pattern. The contact pattern should be centered on the tooth face with 50-70% face width coverage and 40-60% tooth height coverage. Edge contact or improper patterns indicate misalignment, incorrect helix angle, or manufacturing errors. For critical applications, we can provide contact pattern documentation with inspection reports.

Yes, for aerospace applications we provide complete documentation including AS9102 First Article Inspection Reports, material certifications (MTR), heat treatment certifications, gear inspection reports showing tooth profile, lead, pitch, and runout measurements, and contact pattern verification. We can also provide additional testing such as magnetic particle inspection, hardness traverses (surface and core), and case depth verification as required by your specifications.