Hobbing, milling, grinding and 5-axis machining of spur, helical, bevel and internal gears. We machine blanks from bar or forging, cut the teeth and hold the bore, face and pitch data in one setup.
Most failures trace back to the blank, the setup or the tooth data. Not the machine.
When the bore is turned on one machine and the teeth are cut on another, the runout stacks. A 0.02 mm offset at the bore shows up as noise and uneven wear across the face width. Turning and cutting the same blank in one fixtured setup removes that stack.
Case hardening moves the flanks. If grinding stock is not planned into the blank, the gear comes back distorted and the backlash is wrong. We leave 0.1–0.3 mm on the flanks and grind after hardening to restore the profile.
A gear that measures well on the OD can still have the wrong lead or profile. Without a chart you are guessing. We supply inspection reports on request so your engineer can check pitch, runout and profile against the drawing.
Hobbing a one-off gear is not expensive. Cutting a mold or a die for a design that may change is. We cut prototypes from bar stock with no minimum order quantity, so you can test the fit before committing to tooling.
The blank, the setup and the tooth data decide whether the gear runs quiet.
Hobbing is the fast way to cut spur and helical teeth. One hob, one pass, and the tooth spacing comes from the lead of the hob rather than from a dividing head. For module 0.5 to 8 gears we hob on a CNC hobbing machine, then deburr and, if the drawing calls for it, grind the flanks.
Not every gear shape works with a hob. Internal teeth, bevel teeth and gears with a shoulder too close to the face need form milling or 5-axis machining instead. We pick the method from the geometry, not from what is free that week.
A gear is only as good as the bore it spins on. We turn the bore, face and any shoulder in one operation, then cut teeth with the part still referenced to that bore. That way the pitch circle runs true to the shaft, and you do not need to correct for runout on assembly.
For tight assemblies we hold ±0.005 mm on critical diameters and control tooth-to-tooth spacing on the machine. Surface finish on the flanks sits around Ra 0.8–1.6 μm after grinding, which is the range that keeps contact noise down in a running gearbox.
Pick the process from the geometry, the load and the batch size.
| Process | Best for | Watch out for |
|---|---|---|
| Hobbing | Spur and helical teeth, module 0.5–8 | Cannot cut internal or bevel teeth |
| Form milling | Large modules, shoulders, odd profiles | Slower per tooth than hobbing |
| 5-axis machining | Bevel, internal, complex flank forms | Higher cycle time on simple gears |
| Grinding | Hardened gears, tight profile bands | Needs stock left on the flanks |
| Casting / forging | High-volume blanks before machining | Tooling cost only pays off at volume |
One shop for the blank, the teeth and the finish.
Hobbed or milled from bar, with the bore turned in the same setup. Module 0.5 to 8, in steel, stainless and aluminium.
Cut on 5-axis centers when a hob cannot reach the flanks. Good for right-angle drives and ring gears.
After hardening, to bring the profile back inside the tolerance band and set the flank finish.
Turning, milling and slotting of the mating parts, so the gear and shaft fit without hand work.
Straight and helical racks cut to length, with the mounting holes drilled in the same setup.
Black oxide, electroless nickel, anodizing and bead blasting for wear and corrosion resistance.
Numbers from our Dongguan and Singapore plants.
| Parameter | Range | Notes |
|---|---|---|
| Module | 0.5–8 | Smaller or larger on review |
| Max part size | 4,000 mm | Maximum processing size |
| Tolerance | ±0.005 mm | ±0.0002 in on critical features |
| Flank finish | Ra 0.8–1.6 μm | After grinding |
| Batch size | 1 to 10,000+ | No minimum order quantity |
| Lead time | 3–5 days | After production start |
Data, not adjectives.
Founded in 2011. Three wholly-owned plants, 7,600 m² of floor space and 150 technicians on the gear and motion parts line.
16 simultaneous 5-axis centers, 12 four-axis mills, 27 three-axis machines and 16 mill-turn centers under one quality system.
Held on critical diameters and bore features. Flank finish to Ra 0.2–0.8 μm when the drawing calls for it.
Quotation and free DFM analysis within 12 hours of receiving a drawing. Production can start within 24 hours.
100% inspection before shipment, with raw material checks, in-process monitoring and final inspection. Reports on request.
Historical late-delivery probability below 2%. We plan grinding and hardening steps into the schedule instead of after it.
Transmission and drive gears that have to run quiet at speed. IATF 16949:2016 process control, profile ground after hardening.
Planetary and harmonic drive parts where backlash decides positioning accuracy. Bore and teeth cut in one setup.
Racks, pinions and large spur gears up to 4,000 mm. Form milling for modules a hob cannot reach.
Small precision gears in stainless and titanium. ISO 13485:2016 controls, clean deburring, inspection reports on request.
A drawing with module, number of teeth, pressure angle, helix angle and the tolerance band on the bore and flanks. If the drawing is incomplete, send what you have and the mating part.
We run a free DFM analysis within 12 hours and flag anything that will be hard to cut or measure before the quote goes out.
Spur, helical, bevel, internal, racks and pinions, in module 0.5 to 8. Larger modules are possible on review.
Simple spur and helical gears are hobbed. Bevel, internal and complex flank forms are cut on 5-axis centers.
We plan hardening into the routing and leave 0.1–0.3 mm of stock on the flanks so the distortion can be ground out afterwards.
Grinding after heat treatment is what restores the profile and sets the finish to Ra 0.8–1.6 μm. Cutting the teeth and skipping the grind only works on soft gears.
±0.005 mm on critical diameters, with the bore and teeth sharing the same datum so runout does not stack.
If your assembly needs tighter than that, tell us the fit and we will say whether it is realistic in the material you picked.
No minimum. We cut one-off prototypes and runs over 10,000 parts on the same line.
For a single gear the cost is mostly setup and programming time, so a prototype is cheap. Tooling only makes sense once the design is frozen.
Steel 1045, 4140, 4340 and tool steel, stainless 303, 304, 316, 17-4PH and 440C, aluminium 6061 and 7075, plus titanium TC4 and plastics such as POM and PEEK.
The material decides the cutting speed and whether hardening is worth it. A plastic gear will not hold the same profile band as a ground steel one.
Raw material check on arrival, in-process monitoring during cutting and grinding, and 100% inspection before shipment.
Pitch, runout and profile reports are available on request. If you need a first article report, ask for it at the quote stage so it is planned into the schedule.
Uploads are secure and confidential, and we sign an NDA on request before drawings are shared.
Gear drawings usually carry the whole transmission layout, so this is standard practice for us rather than an exception.
Upload the drawing and the mating part. We run a free DFM analysis, then quote the blank, the teeth and the finish as one job.
12-hour quote100% inspectionNo MOQ
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Upload your 3D model or 2D drawing and get a quotation with a free DFM analysis. Maximum processing size 4,000 mm.
CNC Metals 13 grades
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