Manufacturing process

Gear Manufacturing

Gear manufacturing produces toothed components — spur, helical, bevel and worm gears, splines and racks — by cutting, heat treating and finishing teeth to a defined accuracy.

Process overview

Gear manufacturing covers the production of spur, helical, bevel and other toothed components using processes selected for geometry, accuracy and production volume. Manufacturing can combine cutting, hobbing, shaping, grinding, heat treatment and inspection operations. Requirements may include gear geometry, module or pitch, material, hardness, accuracy class, surface finish and dimensional verification.

Gear blanks are usually turned first; the teeth are then generated by hobbing, shaping, milling or broaching. Hobbing is the most common method for external spur and helical gears, shaping is used for internal gears and gears close to shoulders, and power skiving is increasingly used for internal teeth. Bevel gears need dedicated machines. After cutting, gears are often case hardened or nitrided and then ground or honed where noise, load capacity or accuracy require it.

Gear accuracy is expressed in quality grades such as ISO 1328 or AGMA classes, covering profile, helix and pitch deviations. Higher grades generally call for ground teeth and more inspection. Gear measuring machines and double-flank testers verify the geometry, and customers may ask for inspection charts per gear or per batch.

Typical capabilities & what manufacturers can produce

What manufacturers can produce

  • Spur and helical gears
  • Internal gears and ring gears
  • Splined shafts and hubs
  • Bevel gears and worm gear sets
  • Racks and pinions
  • Ground, high-accuracy gears for drives and gearboxes

Capabilities under this process

Suitable materials

Materials commonly used with this process — an editorial reference, not a statement about facilities in the Metraxio network. Suitability always depends on the part and its application.

Relevant industries

Industries whose Metraxio industry guides list Gear Manufacturing as a common process, with the typical use in each.

What buyers should specify

The details that make Gear Manufacturing quotes comparable and let facilities be assessed on the right criteria.

Gear data
Module or diametral pitch, number of teeth, pressure angle, helix angle, profile shift and face width.
Accuracy grade
ISO 1328 or AGMA quality class, and which parameters are critical.
Material and heat treatment
For example 16MnCr5 carburised or 42CrMo4 nitrided, with case depth and hardness.
Tooth finishing
Hobbed, shaved, ground or honed.
Mating data
Centre distance, backlash and mating gear information.
Gear inspection
Measurement reports and double-flank testing.
Quantity
Prototypes, spare parts or series.

On Metraxio these details become a structured manufacturing requirement. Processes, capabilities, materials, certifications and part size are checked against facility profiles; tolerances, finishes and inspection details travel with your drawings and are reviewed during quoting rather than used as automatic filters.

Frequently asked questions

Do my gears need grinding?

Ground teeth are commonly needed for high accuracy grades, low noise or high load after heat treatment. Many industrial gears are hobbed and used without grinding.

What data does a gear supplier need?

At minimum module, tooth count, pressure angle, helix angle, face width, accuracy grade, material and heat treatment — ideally on a drawing with a gear data table.

Can gears be made from plastic?

Yes. Plastic gears are typically injection molded or machined from POM or nylon for quiet, lower-load applications.

Start a Manufacturing Project

Upload a drawing or describe what you need. Process context from this page can be reviewed before it becomes a structured requirement.

Suggested process is prefilled for review — you can change it.