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In general, the term “gear” in an industrial or manufacturing context refers to a component within a complex mechanical assembly which performs a specified task. Usually shaped in the form of a toothed wheel, a gear may assist an operator in steering a vehicle, or in changing the direction of a rotating power drill or other moving tool. Today, gears perform vital roles within machines utilized in virtually every industry.


About Gears

Gears, sometimes described as “cogwheels”, typically resemble toothed wheels in shape. They typically rotate within a mechanical assembly. As the wheel turns, its teeth (or “cogs”) connect with meshed gear cogs or with other meshed parts in the assembly to perform designated actions.

Inventors have developed many different types of gears. Gears today reach customers in an impressive variety of sizes and shapes. These important mechanical parts often play essential roles within machinery.

Gears frequently help operators control the direction of the movement of a machine. For example, by shifting between automotive gears, a driver may operate a vehicle in a forward or a reverse direction. Due to the precision of their actions, gears typically require careful manufacturing within tight tolerance ranges. They must also resist breaking, bending and fracturing.


Types of Gears

As a mechanical component, a gear sometimes performs essential functions in machines of different sizes and dimensions. Product developers have created many types and styles of gears. Just consider a few of the most important gears widely used by modern manufacturers:

Spur Gears (“Straight Cut Gears”): One of the most in-demand type of gears, these disk-shaped components typically include holes machined into the wheel to contain shafts, and sharp straight exterior pointed teeth along the rim. They may require precision engineering to work correctly within complex assemblies.

Helical Gears: These gears often resemble spur gears in appearance. However, the teeth of helical gears angle across the mesh gear contact surface. They therefore will contribute to a more gradual meshing process, resulting in quieter, smoother gear functioning.

Bevel Gears: The type of flexible gear capable of contacting a moving mechanical part in an assembly at an unusual angle; it does not require the mounting of the gear along a parallel axis, for instance, and will function in right angle mountings.

Worm Gears: These very strong gears assist machine operators in rapidly reducing operational speeds. A form of helical gear, the teeth of a worm gear resemble a long helical thread.

Ratchet Gears: Manufacturers design these hollow precision-engineered gears to operate in a unidirectional manner within a mechanical assembly.

Pinion Gears: Small gears possessing a limited number of teeth.

Rack And Pinion Gears: Widely utilized in the automotive industry within steering systems, this type of component relies upon a disc-shaped pinion gear. Its teeth mesh onto a moving toothed rod called a “rack”.

Planetary Gears (“Epicyclic Gears”): A complex device, a planetary gear can ensure inputs and outputs within a mechanical assembly align with precision. One, or several, gears within the epicyclic gear assembly itself will typically move.


Gears: Materials And Applications

Some industries display a high demand for gears as industrial components. Since gears potentially serve a multitude of purposes, these items often require the use of carefully selected raw materials. Gear designs sometimes vary widely.


The materials used in gear manufacturing display great diversity. They vary depending upon the component’s intended use. Steel remains the most frequently utilized metal for this purpose, since it offers both strength and manufacturing cost benefits. However, manufacturers do sometimes employ other raw materials in gear construction, including carbon fiber, aluminum, brass, bronze, copper, cast iron, ductile iron, stainless steel, and several types of plastics (including nylon).


Gears enjoy numerous applications. They serve as components of assemblies used in the automotive, aerospace, agricultural, energy, electronic, and consumer goods industries. Gears occur in a multitude of sizes and shapes.


Custom Gears

Currently many companies producing proprietary products for the commercial marketplace also seek to design and develop custom gears specifically tailored to function within their brands. You’ll want to contact Bunty LLC first if you seek assistance with this type of project. We offer an impressive variety of useful resources and experienced personnel to help you create cost-effective, reliable gears and other customized mechanical components.

Custom Cut Gears

In some situations, manufacturers require assistance in obtaining custom cut gears. These components, machined to conform within specific operational parameters, may become essential if a company cannot locate critical spare or replacement parts in the commercial marketplace, for instance. If your firm requires assistance obtaining custom cut gears for its machines, consider contacting Bunty LLC for fast, expert assistance in manufacturing gears to order.

EDM Gears

This term describes a specific type of manufacturing process which depends upon electronic discharges (or sparking) to produce desired shapes during the machining process. Bunty LLC offers a valuable resource for companies seeking assistance with EDM gears. We assist firms seeking to use electronic discharges or sparking to help shape gears during the machining process.


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From a contract manufacturing firm, BuntyLLC evolved into a full service custom machined, forged and cast metal parts fabrication enterprise. We supply global solutions from our headquarters in Greenville, South Carolina.

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