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Custom precision gears are critical components in robotics, medical devices, automotive subsystems, and industrial drives. If you're searching for gear design & manufacturing services, this guide explains real-world manufacturing choices, cost drivers, quality checkpoints, and how to pick a supplier that delivers on tolerance, finish and repeatability.
Why precision matters: tolerances, life, noise and efficiency
Typical processes and when to use them (hobbing, shaping, grinding, additive)
Materials, heat treatment and surface finishes for gears
A representative/composite case study with measured outcomes
Cost model + sample calculation so buyers can compare quotes
SEO-focused long-tail keyword list and FAQ (ready for Schema markup)
High-precision gears affect backlash, torque ripple, NVH (noise-vibration-harshness) and service life. For example, reducing pitch error from 0.02 mm to 0.005 mm can noticeably reduce vibration in precision stages — that’s why inspection (CMM, gear rolling test) is part of the process, not an afterthought.
Key buyer signals: required module/DP, number of teeth, face width, material, hardness, tolerance class (e.g., AGMA/ISO), surface finish (Ra), batch quantity, and desired lead time.
Process | Typical use-case | Accuracy (typical) |
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Hobbing (CNC) | Volume production, spur/helical | ±0.01–0.05 mm (bulk hobbed) |
Shaping | Small gears, internal gears | ±0.01–0.05 mm |
Gear grinding | Final finishing for high accuracy | ±0.002–0.01 mm |
Broaching | Internal splines/gears | tight tolerances for splines |
CNC milling/turning | Prototypes / nonstandard geometries | ±0.01–0.05 mm |
Additive + finishing | Complex geometry, low volume | depends on post-machining |
Heat treatment (carburize/nitriding/induction) | Increase surface hardness & wear life | hardness 48–62 HRC (process dependent) |
When to choose grinding: use when AGMA/ISO class requires low pitch/lead error (for servo or aerospace).
When to choose hobbing: efficient for production runs where post-grind is optional.
Alloy steels: 4140, 8620 (carburizable) — common for high-load gears.
Stainless steels: 17-4 PH, 304/316 (lower wear resistance unless surface treated).
Bronze/Brass: sliding contacts (worm drives).
Engineering plastics: PA, POM, nylon for quiet, low-load applications.
Typical treatments: carburizing + quench & temper (surface hardness 55–62 HRC), nitriding (good for fatigue, lower distortion), induction hardening (local hardening).
Surface finish targets: gearbox gears often specify Ra 0.4–1.6 µm after grinding/polishing.
Representative composite case study (built from multiple production projects):
Project: 500 units — helical spur gear set for an industrial actuator. Material: 8620, carburize to 0.8 mm case depth, final grind to AGMA Q10 equivalent.
Measured results: average pitch error reduced from 0.018 mm (hobbed) to 0.004 mm after finishing; runout <0.005 mm; NVH reduced by ~30% (subjective comparison on test bench). Lead time: 6 weeks from approved drawing. Scrap rate: <1% after process optimization.
What we learned: early prototyping + single-sample inspection cuts iterations. Implementing a pre-heat-treat stress-relief step reduced post-treat grinding by ~20% (time saved, fewer reworks).
Main cost drivers:
Material and material volume
Cycle time for cutting & finishing (hob vs grind)
Heat treat type and distortion control (fixturing, quench media)
Inspection & certification (CMM reports, runout, tooth form)
Batch size and setup amortization
Sample calculation (illustrative example only):
Assumptions: 100 pcs, spur gear, 4140 preform, module 1.0, face width 12 mm.
Raw material + blanks: USD 2.50/pc
Hobbing & deburr: USD 6.00/pc
Heat treat & finish grinding: USD 8.00/pc
Inspection & packaging: USD 1.50/pc
Overhead & margin + tooling amortization: USD 6.00/pc
Estimated unit price: USD 24.00/pc (example to compare quotes — ask vendors for the same cost breakdown)
Always request: material certificates (EN/ASTM), heat-treat report, and first-off inspection report.
First Article Inspection (FAI) with CMM report
Tooth form/lead/pitch error reports (gear rolling or CMM)
Hardness profile (case depth report)
Material certificates (mill test report)
Traceable lot coding and packaging instructions
7 Swords Precision: Your Trusted Partner in Custom CNC Machining
As a leading provider of custom CNC machining parts and components, 7 Swords Precision specializes in prototype turning and milling using high-quality metal materials. We deliver precision-engineered products tailored to the unique requirements of various industries. Our commitment to excellence has established us as one of the top CNC manufacturing suppliers in the market.
We are proud to hold several production certificates for our CNC machining services, which demonstrates our commitment to quality and customer satisfaction. Our team follows strict quality control procedures to ensure that every part we produce meets the highest standards of quality and accuracy
Processing |
CNC Turning, CNC Milling, Laser Cutting, Bending, Spining, Wire Cutting, Stamping, Electric Discharge Machining (EDM), Injection Molding |
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Materials |
Aluminum: 2000 series, 6000 series, 7075, 5052, etc |
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Stainlesss steel: SUS303, SUS304, SS316, SS316L, 17-4PH, etc |
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Steel: 1214L/1215/1045/4140/SCM440/40CrMo, etc |
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Brass: 260, C360, H59, H60, H62, H63, H65, H68, H70, Bronze, Copper |
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Titanium: Grade F1-F5 |
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Plastic: Acetal/POM/PA/Nylon/PC/PMMA/PVC/PU/Acrylic/ABS/PTFE/PEEK etc |
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Surface Treatment |
Anodized, Bead Blasted, Silk Screen, PVD Plating, Zinc/Nickl/Chrome/Titanium Plating, Brushing, Painting, Powder Coated, Passivation, Electrophoresis, Electro Polishing, Knurl, Laser/Etch/Engrave etc |
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Tolerance |
±0.002 ~ ±0.005mm |
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Surface Roughness |
Min Ra 0.1~3.2
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