Let’s face it: off-the-shelf gears often fall short of meeting the unique demands of specialized machinery that is so commonplace in today’s manufacturing landscape.
This is especially true for businesses operating in sectors like automotive, aerospace, heavy equipment, and industrial automation, where performance hinges on precision.
Standard gear options can and most likely will compromise efficiency, durability, and compatibility, leading to higher maintenance costs and operational downtime.
That’s where custom gear manufacturing becomes essential.
So, let’s explore the benefits of custom gear manufacturing, the types of gear Bunty provides, and why partnering with us can offer you a unique strategic advantage for your operations.
For businesses that rely on mechanical power to run their operations, gears are mission-critical components that can make or break system performance.
That’s why working with a custom gear manufacturer can provide gears that go far beyond what their standard, mass-produced counterparts can offer.
Here are some of the main reasons why many companies have turned and are turning to custom gear solutions.
Reputable custom gear manufacturers invest in state-of-the-art production equipment, which includes multi-axis CNC machining centers, precision gear hobbing machines, and high-accuracy gear grinding systems.
These technologies enable the production of gears with tight tolerances, precise geometry, and exceptional surface finishes, often in the range of ±0.001 inches or better.
In addition to machinery, advanced quality control systems, such as coordinate measuring machines (CMMs), optical comparators, and in-line inspection processes, are also used by gear manufacturers to ensure consistent quality and compliance with industry standards.
This level of precision is crucial for sectors like aerospace, medical devices, and robotics, where even minor deviations can lead to performance failure or safety risks.
Time-to-market is a key factor in today’s product development cycles.
That is why custom gear manufacturers often offer in-house design, prototyping, and low-volume production services, enabling their clients to test and refine gear designs rapidly.
Whether it’s modifying a tooth profile or adjusting the center distance, changes can be implemented quickly and without the delays typically associated with third-party vendors and overseas suppliers.
A streamlined manufacturing process can reduce product development timelines, helping businesses stay competitive and respond to market demands faster.
Custom gear manufacturing offers very broad material and design flexibility, which allows clients to specify the exact alloy, hardness, and finish required for their application.
Whether the gears need to withstand high torque, extreme temperatures, or corrosive environments, custom gear manufacturers can recommend the most suitable materials to fit application needs.
Some of the materials that gear manufacturers typically recommend include:
Custom manufacturing also supports non-standard sizes, complex geometries, and specialized tooth profiles.
This includes helical, bevel, and worm gears to ensure that the final product fits seamlessly into the client’s machinery.
There’s no doubt that working with a custom gear manufacturer can supply businesses with a competitive edge over their competition via enhanced precision, accelerated development, and tailored solutions that off-the-shelf gears simply can’t provide.
In the following section, we’ll look at the specific types of custom gears Bunty offers and how they support a wide range of industrial applications.
When it comes to gears, we believe that custom gear manufacturing is more than just shaping metal.
It’s a precision craft that should be backed by advanced technology and engineering expertise.
Bunty offers custom-cut gears tailored to meet the unique requirements of industrial clients across a broad range of sectors.
One of our key differentiators in our gear manufacturing process is our ability to support Electrical Discharge Machining (EDM), which is a highly precise, non-contact method that is ideal for intricate gear profiles and hard-to-machine materials.
EDM machining uses electrical discharges to erode material from a metal workpiece with extreme accuracy.
This process allows us to manufacture gears with complex shapes, tight tolerances, and fine details, even in very hard metals like tool steel and exotic alloys.
EDM is especially beneficial when working on:
By leveraging EDM, we can achieve unparalleled precision that fosters the production of custom gears that meet the demanding specifications of a variety of industries.
At Bunty, we offer a wide array of gear types, each serving distinct functional needs for various mechanical systems.
| Spur Gears (Straight Cut Gears) | Disk-shaped with straight, pointed teeth that run parallel to the axis. They offer high-efficiency power transmission and are often custom-machined to fit complex mechanical assemblies where precision shaft alignment is essential. |
| Helical Gears | Their design enables a more gradual contact between teeth, reducing vibration and increasing load capacity. They are ideal for automotive transmissions and heavy machinery. |
| Bevel Gears | They allow power transmission between shafts at varying angles (typically 90°). Their cone-shaped design makes them suitable for equipment with non-parallel axes, such as differential drives and certain types of conveyors. |
| Worm Gears | They consist of a worm (screw-like shaft) that meshes with a toothed wheel. Their self-locking capability makes them ideal for lifts, hoists, and machinery that must hold a position securely when powered off. |
| Ratchet Gears | Ratchet gears are used in applications requiring intermittent motion or directional locking. Bunty machines these components with high precision to ensure durability and reliability under heavy loads. |
| Pinion Gears | They have fewer teeth than other kinds of gears and are often paired with larger gears or racks to deliver rotational motion. They are commonly used in compact assemblies where space is limited. |
| Rack and Pinion Gears | These gears do not consist of just gears but rather incorporate a system that meshes a round pinion gear with a linear toothed rack. This configuration is widely used in automotive steering systems and industrial automation, where rotary motion needs to be converted to linear motion. |
| Planetary Gears (Epicyclic Gears) | These complex assemblies involve a central “sun” gear, multiple biting “planet” gears, and an outer “ring” gear. They offer high torque density and precision, making them indispensable in robotics, aerospace mechanisms, and high-efficiency gearboxes. |
As you can see, our gear manufacturing capabilities span a wide range of gear types and machining methods.
In other words, the flexibility in design, materials, and production techniques we offer when it comes to custom gear manufacturing ensures that our clients receive gears tailored for optimal performance and reliability.
Why do businesses across the globe trust Bunty when it comes to sourcing high-quality, precision-engineered gears?
One simple reason: expertise backed by experience.
With decades of industry knowledge and state-of-the-art manufacturing facilities, Bunty has become a recognized leader in custom gear manufacturing.
Source: Bunty
Our company serves a diverse portfolio of industries, each with its own set of performance challenges and engineering specifications.
For example, our custom gears can be used for:
This broad industry experience allows us to anticipate the functional demands of different applications and recommend optimal gear configurations, materials, and treatments.
With offices in both the United States and Asia, we supply our clients with fast turnaround times and flexible production schedules.
Our international footprint means we can accommodate small prototype runs, as well as full-scale production with equal efficiency.
What is more, every gear we produce is manufactured in modern facilities to ensure consistency and compliance with international standards.
Source: Bunty
Bunty also holds certifications that demonstrate our commitment to quality, precision, and process control.
Whether you require AS9100 compliance for aerospace, ISO 9001 for general manufacturing, or specialized materials testing, we have the certifications and systems in place to meet your expectations.
From concept to completion, every one of our gears is produced with tight tolerances and reliable repeatability, ensuring it performs exactly as intended during real-world conditions.
Contact BUNTY Today
For more information about custom gear manufacturing and our other capabilities, contact us through our website form or request a quote here. We welcome your inquiries.