Gear Manufacturing
Elimold has many years of experience in custom gear manufacturing services, providing high-quality gears, related components and transmission gear assemblies for medium to high volume parts according to customer specifications. We can also reverse engineer and manufacture your current gears. Contact us now for a free instant quote.
Gear Manufacturer
Elimold is a leading gear manufacturer specializing in custom gears for OEM around the world. Whether we build your gear from start to finish or machine from your blank, our extensive precision gear manufacturing capabilities and services provide high-quality gears to meet nearly every application and the most demanding specifications.
We are able to manufacture all types of custom gears, and there is no project we cannot handle. We are a gear manufacturer that is focused on you and your project and providing quality gears in a timely manner. We are committed to exceeding your needs for gear manufacturing technology from start to finish. Not only are we unique as a manufacturer because we offer an in-house heat treatment and prototyping department, but ultimately, our success is due to our people: a talented, experienced, creative, forward-thinking and responsive team. So whether your project requires full design of a gear, prototyping, pre-production and production services, Elimold has the expertise to handle every step of the gear manufacturing process to meet your needs.
Custom Gear Manufacturing In-House Factory Capabilities
We have grown to an 80,000 square foot in-house gear manufacturing facility with ample room for future expansion. With the expertise to handle every step of the gear manufacturing process. At Elimold, we can provide custom gear manufacturing for a variety of industries, and our in-house shop is equipped with advanced equipment and a team of experienced machinists. As a result, in addition to our regular custom gear production, we can also manufacture high-precision micro gear parts and even fine-tune large components, with horizontal adjustment capabilities up to 260 feet long and 32 inches of swing. And our extensive machining capabilities can manufacture gears up to 30 feet in diameter to meet the large-scale mechanical power of transmission applications. We have the ability to process all types of metals, alloys, and engineered plastics to meet almost all customer needs. In addition to 30-foot diameter gears, we can also produce gears with bore diameters up to 15 feet and weigh up to 80,000 pounds. For larger batches and smaller adjustment requirements, our equipment and capabilities are designed to meet specific production needs. As a full-service custom gear manufacturing facility, we have the ability to manufacture custom gears to exacting specifications, providing the highest quality gear parts in the industry to fully satisfy our customers. Our 24-hour emergency service ensures we are always there for you, contact us now to learn more about our services.
Custom Gear Manufacturing Capabilities & Tolerances
- Spur Gears: Up to 24″ Diameter
- Bevel Gears: Up to 24″ Diameter
- General Turning: Up to 24″ Diameter
- Worm Gears: Up to 24″ Diameter
- Turning: ±0.0002″
- Milling: ±0.0005″
- Hobbing: To AGMA standards
Types of Gear Manufacturing Services
We produce many types of gears, providing gear manufacturing services with unmatched precision and quality, delivering reliability and efficiency for a wide range of applications in various sectors.
- Gear & Pinion
- Helical
- Double Helical
- Herringbone
- Split Herring bone
- Bevel
- Spiral Bevel
- Spur Gears
- Ring Gears
- Eternal Ring Gears
- Rack & Pinion
- Worm Gears
- Double Enveloping Worm Gears
- Hypoid Gears
- Screw Gears
Gear-Related Parts
Gear manufacturing services can specialize in providing gear-related parts.
- Brakes and brake parts
- Chain drives
- Clutches
- Gages and masters
- Gearboxes and transmissions
- Impellers
- Industrial drives
- Splines
- Rollers
- Sprockets
- Timing pulleys
- V-belt pulleys
Custom Gear Supplier
Elimold has the expertise to handle every step of the gear manufacturing process to meet your needs. From design to delivery, we are committed to exceeding your expectations from start to finish. Whether your project requires full design of gears, prototyping, pre-production and production services, we will work with your team to optimize your gear design and help you achieve your production goals. We have invested heavily in cutting-edge technology and state-of-the-art gear manufacturing equipment to ensure we can meet your needs. Our custom gear manufacturing services support our reputation for on-time delivery, competitive pricing and lead times to make your next project a success. We continue to enhance existing lean manufacturing concepts to minimize waste and maximize lead times and services. We are fully committed to improving the value stream and providing our customers with the highest quality, most affordable gear products. At the core of our high-performance performance is excellent gear manufacturing services. We provide quality services at every level to ensure customer satisfaction.
Gear Manufacturing Processes
In the ever-changing world of gear manufacturing, it is crucial to select the most efficient and accurate machining methods and gear tools. The part and production process as well as the batch size determine the choice of tools and gear manufacturing methods. The following are the custom gear manufacturing processes and methods offered by Elimold.
Die Casting
Forging
Extrusion and Cold Drawing
Powder Metallurgy
Hobbing
Gear Shaping
Gear Broaching
Gear Milling
Sunderland Method
Additive Manufacturing
Electrodischarge machining (EDM)
Injection Molding
High Precision Gear Manufacturing Solutions
Elimold specializes in high precision custom gear manufacturing. High performance gears and gear testing are becoming increasingly important for modern, high-speed, precision products in a variety of industries. We maintain strict compliance with NVH (Noise, Vibration and Harshness) standards and requirements. More importantly, we have the resources and processes to ensure that our gears perform to a higher standard. These processes include advanced 100% noise signature analysis on all NVH critical components, capable of isolating ghost noise and other extremely subtle sources of harmful vibration. Our in-house tool room department can expedite machining work on any specific component to reduce time. In our metrics and results driven production environment, we can perform advanced 100% noise signature analysis on critical components, capable of isolating ghost sequence noise and other extremely subtle sources of harmful vibration.
Prototype and Full Production Manufacturing
The Elimold engineering team is comprised of highly skilled craftsmen who are able to deliver high-quality custom gears that meet or exceed OEM requirements. Our engineering team uses only premium materials and high-grade tools. As a result, we are fully prepared to provide you with prototypes from bar stock development to finished products. We will then mass produce the finest precision gears, up to 10,000 parts per month. We provide personalized attention to specific orders and fast turnaround. Our rapid prototype service provides parts that meet very tight tolerances for further development. Thanks to Elimold’s efficient workflow, skilled team members and fast turnaround times, our custom gears are reliable and keep your manufacturing plant running. In addition, we can provide technical support for each of your products. Our engineers are always available to discuss your application and gearing needs.
Ready to start your next custom gear project?
Elimold offers exceptional custom gear manufacturing services for a wide range of applications. Our in-house gear manufacturing shop combines technical expertise with extensive gear manufacturing capabilities to provide high-quality prototypes and production parts. Our stringent quality control system also ensures that we can efficiently meet your unique needs. Contact us now for a free instant quote.
Gear Assembly Capabilities
Elimold can produce assemblies to meet your needs. Gears and related products and shafts can be made into assemblies from the smallest to the largest number of components, regardless of the number of parts in each assembly. Assemblies can be composed of one or more of our standard or custom gears, and Elimold can provide custom gear system related assembly services. Finished gears can be assembled into a gear system and functionally tested to verify their performance under operating conditions. This may involve running the gear system at various speeds and loads to ensure smooth operation, correct tooth meshing and minimal backlash.
Capabilities to Meet Challenging Gear Designs
We have the technical capabilities and equipment to process challenging gear parts. We are able to provide high surface finishes and are well suited for forming internal gears, circular and non-circular holes, splines, keyways and helices. We can manufacture complex close tolerance internal configurations for “ultra-quiet” gear systems. And we have been steadily investing in a mature production quality management system. We have built our entire manufacturing process around meeting the needs of challenging gear designs. We not only provide precision and accuracy, but also high-performance, close tolerance gears that meet the most stringent specifications and critical dimensional/surface finish requirements. Elimold can help you optimize your gear system for optimal efficiency and durability, and improve the performance of your drivetrain. We can also make your plans fit the scale of production and be cost-effective.
Material Options
Gear manufacturing services are available in metal and plastic as well as other material options.
Metal materials
- Aluminum
- Brass
- Bronze
- Cast iron
- Magnesium
- Powder metal
- Steel
- Titanium
Plastics and Other Materials
- Acetal
- Ceramic
- Nylon
- Phenolic resins
- Polycarbonate
- Fiber-reinforced plastic (FRP)
- Rubber
- Delrin (DuPont)
Post-processing processes for gear manufacturing
Elimold can provide a range of treatments, including heat treatment to enhance fatigue properties, as well as dimensional correction and surface finishing.
- Grinding
- Lapping
- Honing
- Shaving
- Polishing
Heat Treating Services
Gears are heat treated after machining to improve their mechanical properties. This typically involves processes such as carburizing, quenching and tempering to increase the hardness, strength and wear resistance of the gear. Heat treatment also helps to relieve internal stresses created during machining.
Elimold has in-depth knowledge and expertise in a variety of heat treatment operations, including carburizing, austenitizing, quenching, tempering, sub-zero heat treatment, nitriding heat treatment, continuous and batch carburizing heat treatment and induction hardening for bevel gears, cylindrical gears, bearing rings and various other components.
Customer Service and Quality Management
Our custom manufacturing supports our reputation for on-time delivery, competitive pricing and lead times to make your next project a success. We continue to enhance existing lean manufacturing concepts to minimize waste and maximize lead times and service. We are fully committed to improving the value stream and providing our customers with the highest quality, most affordable custom gear products.
At the core of our high performance record is exceptional gear manufacturing service. We “meet” any level of customer service demand. This means we are flexible and adaptable enough to either deliver on a regular basis or react and respond to a fault condition. All of our custom gear manufacturing team members are dedicated to the pursuit of excellence in quality, customer satisfaction and continuous improvement of our processes, products and services. Embedded in our business and quality management systems are various processes that provide the foundation for our commitment to strive to exceed our customers’ expectations.
Inspection Equipment
- Gleason 475 Gear Checker (2 Machines)
- Keyence IM Optical Comparitor
- Jenoptik Opticline Shaft Scanner
- Zeiss o-Inspect 543 CMM
- Parkson
- Hardness Tester;
- Optical Comparators;
- Profilometers;
- Surface Plates;
- Gage Blocks;
- Micrometer Sets;
- Dial Bore Gages;
- Plug Gages
- Thread Gages
Quality Standards
Quality standards and certifications for custom gear manufacturing services include:
AS9000
AS9000 is a standard known as the Aerospace Basic Quality System Standard. Its scope is “To ensure customer satisfaction, aerospace manufacturers must produce world-class quality products at the lowest possible cost.”
QS 9000
QS 9000, short for Quality System Requirements, is an international quality management system standard for the automotive industry. All automotive component manufacturers must comply with the standard for product materials, production and service parts, heat treatment, painting, plating, and other finishing services.
ISO 9001
ISO 9001 is part of the International Organization for Standardization (ISO) 9000 series of quality management system standards. It is designed to help organizations ensure that the needs of customers and other stakeholders are met. The document covers, among other things, ensuring that the quality policy is a formal statement from management but understood by all employees; that decisions about the quality system are based on recorded data; that the system is audited regularly, etc.
MIL-SPEC
MIL-SPEC is a military standard designed to ensure interoperability with multinational partners and between military services. Information sharing between systems and personnel requires standard data and equipment interfaces and performance requirements.
Applications
Industries served include:
- General Industrial: power transmission and machinery application; wide range of possible uses.
- Aerospace: aerospace applications, or rated to aerospace or aviation standards.
- Agriculture: use in tractors, combines, planters, seeders, or other farming or agricultural equipment.
- Automotive: use in automobiles, trucks, and other vehicles, or rated to automotive standards or specifications.
- Construction: heavy equipment such as construction or earthmoving machinery, construction site elevators, concrete or asphalt machinery, etc.
- Machine tools: suitable for uses in manufacturing equipment such as mills, lathes, grinding machines, presses, etc.
- Marine: designed or rated for use on ships or shipboard equipment, offshore installations, etc.
- Heavy transportation: suitable for use with heavy trucks, trains, etc., or rated to applicable standards in those industries.
- Material handling: handling applications such as conveyors, winches, automatic cranes, hoists, hoppers, etc.
- Medical and pharmaceutical: Designed or rated for use in medical or pharmaceutical machinery such as pump motors, sanitary transfer machines, or other health-related equipment.
- Military: military or defense equipment rated or designed.
Petrochemical – oil and gas exploration, drilling, and processing machinery. - Power generation: equipment for use in power plants and associated equipment such as ejectors, steam recovery equipment, power plant cooling, generators, etc.
- Robotics: gearing and machinery for precision automation robotic equipment, including robotic welding and assembly machinery, pick and place systems, robotic cranes and other automated equipment.
Request Your Free Gear Manufacturing Quote Today
After receiving your drawings, our engineers will analyze your custom Gear Manufacturing parts right away. We actively work with you to clarify all details before providing a quote that is both economical and accurate.