Custom Precision Gear Manufacturer
- Precision metal and engineering plastic parts machining
- From rapid prototyping, low-volume orders to production requirements
- ISO9001 certified
- On-time delivery
- High cost performance
- Technical support
Why Choose Our Custom Gear Machining Services?
DSR is a professional CNC manufacturer capable of developing reasonable customized gear solutions for different customers. For gear manufacturing, DSR has accumulated many years of machining experience. The entire process, from gear hobbing and gear grinding to heat treatment, is completed in our factory. This ensures we maintain excellent control over product quality, delivery times, and customer requirements.
Whether you are developing a new transmission system, replacing obsolete gears, or looking to address noise, runout, or service life issues with existing parts, our team will first work with you to identify the key parameters that affect meshing. We will then discuss gear tolerances, pricing, and delivery times. If you have any needs, don’t miss the opportunity to partner with us!
What Needs To Be Specified On Gear Drawings For Quoting?
We have always focused on high-quality custom gear manufacturing, strictly adhering to your specifications to produce the required gear products. However, your drawings only specify the outer diameter, bore diameter, and number of teeth, which is usually insufficient for us to determine the tooth profile, machining methods, and inspection costs. The more complete the information provided below, the better DSR can minimize the need for repeated confirmations and provide more reliable estimates regarding the manufacturing process and price.
| Required Parameter | Why It Affects Manufacturing or Quotation |
| Gear Type | Determines applicable equipment, cutting tools, fixturing, and measurement methods |
| Module or Diametral Pitch (DP) | Defines the basic tooth size; also affects tool selection and stock allowance |
| Number of Teeth | Related to indexing, pitch diameter, undercut risk, and mating relationships |
| Pressure Angle | Must match the mating gear; cannot be inferred from appearance |
| Helix Angle & Hand | Critical input for helical gear manufacturing and mating |
| Pitch Diameter, Outside Diameter & Face Width | Affects blank selection, tool travel, rigidity, and machine capacity |
| Bore, Keyway, Splines & Hub Features | Affects clamping datums, concentricity, process sequence, and cost |
| Profile Shift Coefficient / Tip Relief / Modifications | Changes tooth thickness, center distance, strength, and contact pattern |
| Backlash Requirement | Must be evaluated together with center distance, thermal expansion, lubrication, and system tolerances |
| Accuracy Grade & Standard Version | ISO, AGMA, DIN standards are not interchangeable; grade dictates machining and inspection routes |
| Material & Supply Condition | Affects machinability, heat treatment response, distortion, strength, and wear resistance |
| Heat Treatment Requirements | Should specify type, surface/core hardness, effective case depth, and inspection criteria |
| Tooth Surface Roughness / Finishing Requirements | Affects downstream processes such as gear grinding, honing, or lapping |
| Mating Gear Data & Center Distance | Used to verify parameter compatibility, backlash, and contact pattern |
| Load, Speed, Duty Cycle & Lubrication | Basis for assessing material selection, heat treatment, and functional risk |
| Quantity & Annual Demand | Influences blank sourcing method, tooling, fixtures, and unit cost |
| Inspection Report Requirements | Determines measurement equipment, sampling plan, and documentation cost |
| Target Lead Time | Special materials, tooling, heat treatment, and specialized testing may become critical path items |
What Types of Gears Can We Manufacture?
DSR can customize different types of gears according to your drawings and usage requirements. We strictly follow the ISO 1328 standard to ensure your gear parts achieve high precision and quality.
The structure is direct and has high transmission efficiency. This type of gear is commonly used in parallel shaft reduction, conveying, packaging, and general machinery.
These gears have a high overlap ratio and are suitable for parallel-shaft or offset-shaft transmissions that require smooth operation and high load-carrying capacity.
Bevel gears are used to change the direction of power transmission between intersecting shafts.
These gears are suitable for transmissions with large ratios, compact arrangements, or requiring specific self-locking characteristics.
Internal gears are commonly used in planetary gearboxes and compact transmission systems.
This type of gear is commonly used in linear motion, door control, automation modules and positioning mechanisms.
High torque transmission and precision positioning. They are the most reliable power transmission method in shaft-to-hub connections.
High load bearing and strong wear resistance. Sprockets are irreplaceable core components in heavy-duty, low-speed, high-torque transmission systems.
Planetary gears feature high transmission ratios, high torque density, and compact structure. This type of gear is also the preferred solution for modern high-end reduction transmission systems.
Our Custom Gear Machining Process
A gear may require multiple machining processes to manufacture. DSR supports end-to-end machining and can develop a reasonable manufacturing sequence based on your drawings.
We can use CNC turning and milling to create the gear’s profile, end face, bore, hub, slots, mounting holes, and so on.
We will select appropriate processes from various machining techniques such as gear hobbing, gear shaping, form milling, broaching, or wire cutting based on the tooth profile structure of the gear. Different methods will vary in efficiency and precision.
Heat treatment processes such as carburizing, induction hardening, quenching and tempering, or nitriding can improve the strength and wear resistance of gears.
Processes such as gear grinding, honing, shaving, or lapping can be used to improve the tooth profile, tooth direction, and surface condition of gears.
Advantages of Our Custom Gear Machining Services
Custom gears can meet the specific requirements of various applications. This high degree of customization ensures excellent performance, efficiency and service life of the parts.
Our custom gear services can help you obtain gears with outstanding performance.
Custom gears offer unparalleled design flexibility compared to standard gears. We are capable of producing various types of gears.
Our customized solutions are cost-effective, minimize downtime and improve overall operational efficiency.
We provide reliable delivery solutions to ensure that parts are delivered to you intact.
DSR provides a one-stop service process, so you don’t need to worry about any part of the entire processing workflow. We can properly handle every step.
Strict Gear Quality Inspection Process
DSR’s quality inspection runs through the entire gear production process. When raw materials arrive at the factory, we conduct spectrum and hardness testing on these materials to ensure material quality meets our manufacturing standards.
During the machining process, we will also perform first article full inspection and CMM patrol inspection to ensure specifications meet your requirements. After gear heat treatment, we will verify tooth surface hardness and case depth batch by batch. In addition, we must ensure that gear accuracy can be traced to AGMA 12 / DIN 5 grade.
What Gear Materials Can We Provide?
For parts performance, selecting appropriate materials is usually very important and can effectively extend gear life. When selecting, you need to consider the usage requirements such as part torque, speed, impact, and wear. From heavy-duty transmission to quiet light-duty applications, DSR covers almost all mainstream material systems in gear manufacturing.
| Material Direction | Common Reasons for Selection | Design & Manufacturing Considerations |
| Medium Carbon Steel (e.g., 1045) | Balanced cost and mechanical properties; suitable for moderate-load components | Can be combined with quenching & tempering or induction hardening; distortion and hardness gradient must be evaluated |
| 4140 / 4340 Alloy Steel | Suitable for gears or gear shafts requiring higher strength and impact resistance | Heat treatment condition affects machinability, dimensional stability, and final performance |
| Carburizing Steels (8620, 20MnCr5, etc.) | Achieves wear-resistant hard tooth surface with tough core | Case depth, surface/core hardness, and post-heat-treatment finishing must be clearly specified |
| Stainless Steel | Suitable for corrosive, clean, or special environments | Strength, wear resistance, and heat treatment response vary significantly between grades |
| Bronze / Brass | Commonly used for worm gears, friction reduction, or anti-galling pairings | Must be selected together with worm material, lubrication, speed, and temperature rise |
| Aluminum Alloy | Lightweight with high machining efficiency; suitable for specific light-load mechanisms | Limited wear resistance and load capacity; should not be used solely as a weight-reduction substitute for steel gears |
| Engineering Plastics (POM, Nylon, etc.) | Low noise, lightweight, no corrosion protection needed; suitable for light-load transmission | Moisture absorption, temperature, creep, and dimensional stability affect backlash and service life |
If you already have specified materials and heat treatment, please indicate in the RFQ.
Industries and Applications Requiring Custom Gears
Our custom gears have served multiple industries. Thanks to the flexibility of customization, our gears can be manufactured based on various customer application requirements. And the quality of these gears has also received unanimous recognition from our customers.
DSR’s Custom Gear Machining Capabilities
- Parameter
| Parameter | Capability Range |
| Module | 0.5 – 12 |
| Max Diameter | Ø 800 mm |
| Precision Grade | AGMA 12 / DIN 5 / ISO 1328 |
| Tooth Surface Finishing | Grinding, Honing, Shaving |
| Heat Treatment | Carburizing, Nitriding, Induction Hardening |
| Processes | Gear Hobbing, Shaping, Grinding, 5-axis CNC Milling, Powder Metallurgy, Wire EDM |
Blank forming→Gear cutting→Heat treatment→Finishing.
Hobbing machine, gear shaper, bevel gear generator, gear milling machine, gear grinding machine, gear honing machine and gear shaving machine.
Sizing and Dimension Formulas (Imperial / Diametrical Pitch):
- Pitch Diameter (PD): N ÷ DP
- Outside / Blank Diameter (OD): (N + 2) ÷ DP
- Whole Depth of Tooth: 2.157 ÷ DP
Sizing and Dimension Formulas (Metric / Module):
- Pitch Diameter (PD):m × N
- Outside / Blank Diameter (OD): m × (N + 2)
- Whole Depth of Tooth: 2.25 ± m
For basic dimensional aspects, you can use calipers or gear tooth calipers to measure the tip circle diameter, tooth thickness and other dimensions. For more professional precision measurement, you need to use a gear measuring center.
Gear grinding may be required when, after heat treatment, the gear still needs high tooth profile and tooth direction accuracy, a good tooth surface finish, or more stable high-speed, low-noise performance.
Gear Ratio refers to the ratio between the rotational speed (or number of teeth) of the driven gear and the driving gear in a pair of meshing gears. Its calculation formula:
i = n1/n2 = z2/z1
where
- n is rotational speed;
- z is number of teeth;
- subscript 1 represents the driving gear;
- subscript2 represents the driven gear
We can evaluate based on the project. Please specify the required documents, standards, measurement items and report format when requesting a quote.
Steel, cast iron, copper alloy and plastics.
Determine parameters→strength verification→geometric calculation→precision and process confirmation.
To select a reliable custom gear machining supplier, you need to comprehensively evaluate from five dimensions: technical capabilities, quality control, production equipment, industry experience, and service response.
- Technical capability: Does the supplier have complete gear design and calculation capabilities?
- Production equipment and process: Are the gear processing equipment complete; are comprehensive testing equipment available?
- Quality control system: Has ISO 9001 certification been obtained?
- Materials and supply chain: Can multiple material options be provided?
- Industry experience and service response: Are there successful cases in the same industry?
POM, nylon, PEEK, PC and UHMWPE.
STEP, IGES, PDF, DWG, etc.
