Our CNC Gear Machining Services
Elevate your machinery’s performance with our CNC Gear Machining services—where advanced CNC Technology meets decades of Gear Manufacturing expertise. We deliver high-precision gears (spurs, helicals, bevels, and more) with tight tolerances, durable materials, and superior surface finishes, tailored to automotive, aerospace, and industrial sectors. Partner with us for cost-effective, on-time gear solutions that keep your operations running smoothly.
What Is CNC Gear Machining?
CNC Gear Machining is a computer-controlled manufacturing process that produces gears—mechanical components with toothed surfaces that transmit torque and motion between machine parts. Unlike manual gear cutting (which relies on operator skill and is prone to inconsistency), CNC Gear Machining uses pre-programmed CNC Technology to automate cutting, shaping, and finishing, ensuring repeatable precision.
At its core, the Gear Machining Process involves removing material from a workpiece (usually metal) to create teeth with specific profiles (e.g., involute, cycloidal) and dimensions. Gear Manufacturing via CNC integrates software (CAD/CAM) and advanced machines to control every step—from tooth spacing to tooth depth—making it ideal for both standard and custom gear designs. Whether for small hobbyist parts or large industrial gears, CNC ensures accuracy that manual methods can’t match.
Our Capabilities: What We Can Deliver
Our CNC Gear Services cover a full range of gear types and project scales, from prototypes to high-volume production. Below is a detailed breakdown of our Machining Capacity, Precision Gear Machining skills, and supported Gear Types:
| Capability Category | Details | Specifications |
| Gear Types | Spurs, helicals, bevels, worm gears, internal gears, planetary gears | Module range: 0.5–20 mm; Number of teeth: 5–200 teeth |
| Workpiece Size | Small precision gears to large industrial gears | Max diameter: 1,200 mm; Max weight: 500 kg |
| Production Volume | Flexible for low-batch prototypes and mass production | Prototypes: 1–50 units; Mass production: 10,000–500,000+ units/year |
| Precision Level | Ultra-tight control for critical gear performance | Pitch error: ±0.005 mm; Runout: ±0.003 mm; ISO accuracy grade: 4–8 (per ISO 1328) |
| Customization | Tailored to unique designs and industry standards | Supports custom tooth profiles, materials, and surface treatments |
No matter your gear needs—whether a single custom bevel gear or 100,000 spur gears for an automotive line—our Capabilities are scaled to meet your timeline and quality goals.
Process: The CNC Gear Manufacturing Steps
The CNC Gear Machining Process follows a structured sequence to ensure consistent quality and performance. Below is a step-by-step overview of our Gear Manufacturing Steps, from design to finishing:
- Design & Programming: We start with your 2D/3D CAD model (e.g., STEP, IGES) and use CAM software to create a CNC program. This program defines key parameters: gear type, module, number of teeth, cutting tool path, and feed rates—all tailored to your gear’s function.
- Material Preparation: The chosen material (e.g., steel, brass) is cut into blanks (cylindrical or conical shapes) and heat-treated (if needed) to improve hardness before machining.
- Rough Machining: Using CNC hobbing or shaping machines, we remove excess material to create the basic gear shape. For external gears, hobbing is common; for internal gears, shaping works better. This step gets the gear 80–90% close to its final form.
- Finish Machining: We use precision tools (e.g., gear shapers, grinders) to refine the teeth. This step corrects small errors from rough machining, ensuring accurate tooth spacing, profile, and surface smoothness.
Gear Finishing Process: Depending on requirements, we add Surface Finishing (e.g., grinding, lapping) to reduce friction and wear. We also inspect the gear for dimensional accuracy using tools like gear testers.
Materials: Suitable for CNC Gear Machining
CNC Gear Machining relies on materials that balance strength, durability, and machinability. Below are the Common Gear Materials we work with, along with their Material Properties and ideal uses:
| Material | Hardness (HRC) | Tensile Strength (MPa) | Key Properties | Typical Applications |
| Alloy Steel (4140) | 28–32 (annealed); 50–55 (heat-treated) | 860–1,000 | High strength, wear resistance, toughness | Automotive transmissions, industrial gearboxes |
| Stainless Steel (304) | 18–22 | 515 | Corrosion resistance, hygiene | Food processing machinery, marine gears |
| Brass (C36000) | 15–20 | 310 | Excellent machinability, low friction | Small gears for electronics, instrumentation |
| Cast Iron (GG25) | 180–220 HB (≈18–22 HRC) | 250 | Low cost, good damping capacity | Heavy-duty industrial gearboxes, pumps |
| Titanium Alloy (Ti-6Al-4V) | 30–35 | 900 | High strength-to-weight ratio, corrosion resistance | Aerospace gears, medical equipment |
Our Material Selection process involves collaborating with you to match material properties to your gear’s operating conditions (e.g., load, temperature, environment)—ensuring long-lasting performance.
Surface Treatment: Enhancing Gear Performance
Gear Surface Treatment is critical for reducing wear, improving corrosion resistance, and extending gear life. Below are our Surface Finishing options, along with their benefits and ideal uses:
| Treatment Methods | Surface Roughness (Ra) | Key Benefits | Ideal For |
| Gear Grinding | 0.4–1.6 μm | Ultra-smooth surface; reduces noise and friction | High-precision gears (ISO grade 4–5) for aerospace |
| Carburizing & Quenching | 1.6–3.2 μm | Increases surface hardness (up to 60 HRC); core remains tough | Automotive transmission gears (high load) |
| Zinc Plating | 0.8–3.2 μm | Corrosion resistance; low cost | Gears for outdoor equipment, electrical machinery |
| Lapping | 0.02–0.1 μm | Mirror-like finish; improves tooth contact accuracy | Precision instrument gears (e.g., watches, sensors) |
| Phosphating | 1.6–6.3 μm | Enhances lubrication; prevents rust | Gears in hydraulic systems, industrial pumps |
We tailor Post-Machining Treatment to your gear’s needs—whether you need corrosion protection for marine gears or noise reduction for automotive gears.
Tolerances: Precision for Reliable Gear Function
Gear Tolerances directly impact performance: even small errors can cause noise, wear, or failure. We maintain strict Tolerance Control to meet global standards. Below are our Precision Tolerances for key gear features:
| Gear Feature | Tolerance Levels | Industry Standard (ISO 1328) | Impact on Performance |
| Pitch Error (Single Tooth) | ±0.003–±0.01 mm | Grade 4–8 | Ensures smooth torque transmission; reduces vibration |
| Runout (Radial) | ±0.002–±0.008 mm | Grade 4–8 | Prevents uneven load distribution across teeth |
| Tooth Thickness | ±0.005–±0.02 mm | Grade 5–9 | Maintains proper backlash (gap between meshing teeth) |
| Helix Angle Error | ±0.05°–±0.2° | Grade 5–8 | Critical for helical gears; reduces noise and wear |
Our Machining Tolerances are calibrated to your gear’s ISO accuracy grade—from grade 8 (standard industrial gears) to grade 4 (high-precision aerospace gears).
Advantages: Why Choose CNC Gear Machining?
CNC Gear Machining offers clear benefits over manual or traditional methods. Below are the key Advantages of CNC Gear Machining:
- Superior Precision: With Precision Advantages like ISO grade 4 accuracy, CNC ensures consistent tooth spacing and profile—critical for gears that mesh smoothly. Manual machining often struggles to reach grade 8 or better.
- Cost Advantages: For high-volume production, CNC automates labor-intensive steps (e.g., hobbing, shaping), reducing labor costs by 30–40% compared to manual methods. It also minimizes material waste (less than 5%, vs. 15–20% for manual).
- Flexibility for Custom Gears: CNC easily handles custom designs (e.g., non-standard tooth profiles, internal gears) without retooling—ideal for prototypes or niche applications. Manual methods require new tools for each design.
- Quality Advantages: CNC uses real-time monitoring to detect errors (e.g., tool wear, material defects) early, ensuring 99.9% defect-free production. Manual machining relies on operator judgment, leading to higher error rates.
Faster Lead Times: CNC machines run 24/7, cutting lead times by 50% for high-volume orders. A batch of 1,000 gears takes 1–2 weeks with CNC, vs. 3–4 weeks with manual methods.
Applications Industry: Where CNC Gears Add Value
Our CNC Gear Services support diverse Industry Sectors, addressing unique challenges in each field. Below are key Industry Applications and how we deliver value:
| Industry | Application Fields | CNC Gear Uses | Key Requirements Met |
| Automotive | Transmissions, differential systems, electric vehicle (EV) drivetrains | Spur gears, helical gears, planetary gears | High volume (100,000+ units/year); ISO grade 6–7; noise reduction |
| Aerospace | Aircraft engines, landing gear systems, satellite mechanisms | Titanium alloy gears, bevel gears | Lightweight materials; ISO grade 4–5; high temperature resistance |
| Industrial Machinery | Conveyor systems, pumps, compressors, wind turbines | Large helical gears, worm gears | High load capacity; ISO grade 7–8; corrosion resistance |
| Electronics | Small motors (e.g., drones, robots), 3D printers | Micro gears (module 0.5–1 mm), brass gears | Miniature size; low friction; ISO grade 6–7 |
| Medical | Surgical robots, diagnostic equipment | Stainless steel gears, titanium gears | Biocompatibility; corrosion resistance; ISO grade 5–6 |
Manufacturing Techniques: Advanced Methods We Use
To deliver top-tier gears, we use state-of-the-art Gear Manufacturing Techniques and Machining Techniques. Below are our core methods:
- CNC Hobbing: The most common method for external gears (spurs, helicals). A rotating hob (cutter with spiral teeth) cuts gear teeth as the workpiece spins. Ideal for high-volume production (e.g., automotive gears).
- CNC Gear Shaping: Uses a reciprocating cutter (shaper) to create internal or external gears. Better than hobbing for complex shapes (e.g., internal gears, gears with shoulders).
- CNC Gear Grinding: A finishing technique that uses abrasive wheels to refine teeth. Achieves ISO grade 4–5 accuracy and ultra-smooth surfaces—critical for aerospace or precision instruments.
- 5-Axis CNC Machining: For complex gears (e.g., bevel gears, spiral gears). The 5-axis system adjusts the workpiece’s angle in real time, ensuring accurate tooth profiles on all sides.
Wire EDM (Electrical Discharge Machining): Used for micro gears (module <1 mm) or hard-to-machine materials (e.g., titanium). Uses electrical sparks to cut teeth without physical contact—ideal for intricate designs.
Case Studies: Success Stories from Our Clients
Case Study 1: Automotive EV Drivetrain Gears
Challenge: A leading EV manufacturer needed 50,000 helical gears (module 2 mm, ISO grade 6) for their new drivetrain. The gears required low noise, high durability, and a 4-week lead time—manual machining couldn’t meet the timeline or precision.
Solution: We used CNC hobbing for rough machining and CNC grinding for finishing. We chose alloy steel (4140) heat-treated to 55 HRC, with zinc plating for corrosion resistance. Our 24/7 production line ran 10 hobbing machines simultaneously.
Result: Delivered 50,000 gears in 3.5 weeks with 99.95% defect-free rate. The client reported a 20% reduction in drivetrain noise and a 15% longer gear life compared to their previous supplier.
Case Study 2: Aerospace Landing Gear Bevel Gears
Challenge: An aerospace company needed 200 titanium alloy bevel gears (ISO grade 4) for aircraft landing gear. The gears required high strength (tensile strength >900 MPa) and tight runout tolerance (±0.003 mm).
Solution: We used 5-axis CNC machining for rough shaping and CNC gear grinding for finishing. We heat-treated the titanium alloy (Ti-6Al-4V) to 35 HRC and added a phosphating treatment for lubrication. We inspected each gear with a CNC gear tester.
Result: All gears passed FAA certification. The client noted that the gears handled 20% more load than their previous design, with no wear after 1,000 test landings.
Why Choose Us: Our Strengths as Your CNC Gear Partner
When you choose our CNC Gear Machining services, you get more than a supplier—you get a partner focused on your success. Here are the Reasons to Choose us:
- Expertise & Experience: Our team has 20+ years in Gear Manufacturing, with engineers certified in ISO 1328 and aerospace standards (AS9100). We’ve worked with 500+ clients across automotive, aerospace, and industrial sectors.
- Advanced Equipment: We operate 30+ CNC machines (from Gleason and Mitsubishi)—including 5-axis hobbers, gear grinders, and wire EDM machines. Our equipment is calibrated monthly to maintain ISO grade 4 precision.
- Quality Assurance: Our ISO 9001:2015 and AS9100-certified facility includes in-house gear testers, CMMs, and material labs. Every gear undergoes 3 inspections (pre-machining, mid-process, final) to ensure compliance.
- Flexible Lead Times: We offer rush services for prototypes (as fast as 3 days) and scalable production for high-volume orders. Our 24/7 production line cuts lead times by 30% vs. competitors.
Competitive Advantages: Our in-house material sourcing and waste-reduction processes lower costs by 15–25%. We also offer free design consultations to optimize your gear for performance and cost.