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Custom Gear Machining Services

Custom gear machining for spur, helical, bevel, worm and splined gears, held to ±0.005 mm. Every print is reviewed by an engineer, with no MOQ and prototype gears in 3 days.

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  • ±0.005mm

    Lead Accuracy

  • 3 Days

    Prototype Gears

  • 50+

    Materials

5-axis CNC gear machining cutting helical gear teeth in steel
ISO Certified ISO 9001, ISO 13485, AS9100D
Custom machined gear shaft with spur gears on dark worktable

Custom Gears Made to Print or Engineered

DEK machines custom gears made-to-print or with engineering input on tooth form and material: spur, helical, bevel, worm, splines and gear shafts, for procurement teams and engineers across Europe and North America.

Every print is reviewed by hand, not run through an automated calculator. There is no minimum order quantity, so one replacement gear goes through the same low volume CNC machining process as production. Shafts needing keyways or cross-holes run on 4 axis CNC machining.

Why DEK for Custom Gear Machining

Two decades of precision machining, a large OEM base and engineer-reviewed quotes behind every gear order.

  • 20+ Years Experience

    More than 20 years in precision machining, applied to tooth form, bore fit and runout control on custom gears and gear shafts.

  • 1.2M+ Parts per Year

    Over 1.2M parts machined annually, from single replacement gears to short qualification batches and full production orders.

  • 2,300+ OEM Clients

    More than 2,300 OEM clients in robotics, semiconductor equipment, medical devices, automation, aerospace and automotive.

  • 98.6%+ On-Time Delivery

    An on-time delivery rate of 98.6%+, with prototype gears shipping in 3 days and production lead times quoted per order.

Engineer Review on Every Print

Engineers review every gear print by hand, not through an automated calculator, and flag DFM concerns like tight fillets, thin webs or tolerance stacks before quoting, so problems surface before cutting starts.

Gear Cutting Services & Precision

Gear types, cutting processes, tolerances and heat treatment are specified independently, so you can lock geometry and process separately.

  • Gear Types
  • Processes
  • Tolerances
  • Hardening

  • Gear Types We Machine

    Gear type and cutting process are two separate specs: lock the geometry first, then choose the process.

    • Spur, helical and bevel gears
    • Worm gears and custom sprockets
    • Internal and external splines
    • Custom gear shafts with keyways or cross-holes
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    Parameter Specification
    Part size Up to ~1000 mm
    Gear types Spur, helical, bevel, worm
    Other forms Splines, shafts, sprockets
    Module, face width, OD Engineered to drawing
    MOQ None

  • Gear Cutting Services

    Each cutting process suits different tooth counts, batch sizes and post-hardening hardness levels.

    • Hobbing and shaping for external teeth
    • Shaving and broaching for finish and internal forms
    • Gear grinding after heat treatment
    • EDM for hardened tooth profiles
    See EDM Options
    Parameter Specification
    Cutting Hobbing, shaping
    Finishing Shaving, broaching
    Hardened profiles Gear grinding, EDM
    Second setup features 4-axis machining

  • Precision & Tolerance Capability

    Capability is quoted against the feature, not just the part, and held to the standard your print calls out.

    • No AGMA or DIN grade boxing: numbers held directly
    • In-house CMM tooth-form and bore verification
    • Housing bores via jig boring
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    Parameter Specification
    Tooth profile (5-axis) ±0.01 mm
    Dimensional / lead ±0.005 mm
    Micro-gear pitch (sub-10 mm) ±0.003 mm
    Shaft-bore fit / runout ±0.005 mm
    Part size Up to ~1000 mm

  • Heat Treated and Ground Gears

    Hardening is coordinated to your callout, then teeth are ground in-house to hold final tooth form after hardening.

    • Carburizing, induction hardening or nitriding
    • In-house grinding after heat treatment
    • Final tooth form checked against print
    Get a Quote
    Parameter Specification
    Heat treatments Carburizing, induction, nitriding
    Post-hardening finish In-house gear grinding
    Hardened profiles EDM option
    Verification In-house CMM

Gear Cutting Processes Compared

Choose custom gear machining on a CNC base when the gear needs bores, keyways or cross-holes; finish hardened teeth by grinding or EDM.

Criteria This ProcessCNC Gear Machining Gear Grinding EDM
Best for Full gear and shaft Post-hardening teeth Hardened tooth profiles
Stage Before heat treatment After heat treatment After hardening
Features Bores, keyways, cross-holes Final tooth form Tooth profile
Typical tolerance ±0.005 mm lead Holds final tooth form Per print

Industries Using Custom Gears

Robotics, semiconductor equipment, medical devices, industrial automation, aerospace and automotive drivetrain components.

  • Aerospace

  • Medical

  • Automotive

  • Robotics

  • Semiconductor

  • Electronic

  • Telecom

  • Drone & UAV

  • Energy

  • Oil & Gas

  • Marine

  • Industrial Equipment

  • Construction

  • Agriculture

  • Consumer Products

  • Military & Defense

  • Mining

Gear Features & Challenges We Solve

From micro-gears to 1000 mm shafts, gear work hinges on tooth form, bore fit and accuracy after hardening.

  • Micro-Gears

    Sub-10 mm components with micro-gear pitch held to ±0.003 mm. See our micro machining.

  • Large Gears & Shafts

    Gears, shafts and housings up to about 1000 mm via large part CNC machining.

  • Complex Tooth Profiles

    Complex tooth forms machined on 5-axis geometry, with tooth profile held to ±0.01 mm and checked by in-house CMM.

  • Gear Shafts

    Keyways, snap grooves and cross-holes on a second setup, run on 4-axis to hold position between features.

Common Gear Challenges

  • Accuracy After Hardening

    Carburized, induction hardened or nitrided gears are ground in-house after heat treatment, where most off-the-shelf shops lose accuracy.

  • Bore Fit and Runout

    Shaft-bore fit and coaxiality held to ±0.005 mm, verified by in-house CMM inspection of tooth form and bore.

  • Housing Bore Position

    Housings and bore locations needing positional accuracy separate from the gear run through jig boring.

Certified Quality on Every Gear

IQC, IPQC, FAI, OQC, SPC and CAPA stages under TUV-certified quality systems.

  • AS9100D and ISO 9001 certification logo
    AS9100D

    Aerospace Quality Management System

  • ISO 9001 certification logo
    ISO 9001:2015

    Quality Management Standard

  • ISO 13485 certification logo
    ISO 13485

    Medical Devices Quality Management

50+ Materials for Custom Gears

Metals cover load-bearing gear work; engineering plastics cover low-load gears where weight or chemical resistance matters.

Metals

Engineering Plastics

Not sure which gear material fits? Compare all materials

View All

How to Order Custom Gears

  • 1

    Send Your Print

    2D/3D print with tooth count, module or pitch, material, quantity and tolerances.

  • 2

    Engineer Review

    An engineer reviews the drawing by hand and flags DFM concerns before quoting.

  • 3

    Confirm Order

    Quote, process, heat treatment and delivery schedule confirmed with you.

  • 4

    Cutting & Grinding

    Teeth cut, heat treatment coordinated, then ground in-house to final tooth form.

  • 5

    Inspection & Shipping

    CMM inspection of tooth form and bore, FAI documentation, then shipment.

Custom Gear Machining FAQ

Answers on tolerances, lead times, DFM review and inspection for custom gears.

Where can I get custom gears made?
DEK machines custom gears made-to-print or with engineering support on tooth form and material selection: spur, helical, bevel, worm and splined designs in metals and engineering plastics, with no minimum order quantity.
What tolerances can custom gear machining hold?
Tooth profile on 5-axis geometry holds ±0.01 mm; lead accuracy and shaft-bore runout hold ±0.005 mm; micro-gear pitch on sub-10 mm parts reaches ±0.003 mm. Hardened gears are ground in-house after heat treatment, and an engineer confirms numbers within 6 hours for most parts.
How long does gear production take after the prototype stage?
Prototype gears ship in 3 days. Production lead times depend on tooth count, batch size, heat treatment and finishing steps, so they are quoted per order once your print, quantity and tolerance callouts are reviewed.
Can you flag design-for-manufacturing (DFM) issues before quoting?
Yes. Engineers review every print by hand, not with an automated calculator, and flag DFM concerns like tight fillets, thin webs or tolerance stacks before quoting, so problems surface before cutting starts.
Do you provide inspection reports with gear orders?
Yes. CMM inspection reports and FAI documentation are available for gear orders, generated within the standard IQC/IPQC/FAI/OQC/SPC/CAPA process under ISO 9001, AS9100D and ISO 13485.

Request a Custom Gear Machining Quote

Send a 2D/3D print with tooth count, module or pitch, material, quantity and tolerance callouts. An engineer reviews it before you get a quote.

  • No minimum order quantity
  • Prototype gears ship in 3 days
  • DFM concerns flagged before quoting
  • CMM reports and FAI available
  • 98.6%+ on-time delivery rate
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