When asked to imagine the gear manufacturing process, most people think of some high volume, massive factory, churning out gear after identical gear, to be used in some far off application that demands many copies of the same specific part. They imagine a number of different sizes and shapes of gears, but each belonging to its own category, or its own standard, much in the same way that screws and bolts are listed as different gauges and sizes.
While this is partially true, the reality is that custom made gears, made in quantities as small as one are designed and engineered for a specific and sometimes unique, purpose, are often necessary as part of the manufacturing process. Why is this?
The Importance of Precision
First, you have to understand the importance of precision in gear manufacturing. Gears are used as internal components for systems, and rely on seamless, uninterrupted contact with the other moving parts of that system if the system is to continue working. If a single tooth is misshapen by even a 1/1000thof an inch (1/4 the thickness of an average human hair) , it could result in long-term damage, or the immediate malfunction of the system altogether. Because this precision is so important, oftentimes “standard” sizes can’t get the job done and customer gears are required.
Unique Demands
Though some gears are used in mass-produced consumer products, and can be replicated easily, you should also know that a wide variety of projects require unique demands. For example, one-of-a-kind constructions and mechanisms might have specs that aren’t based on any pre-existing model, and might therefore need a uniquely designed gear to operate..
Reverse Engineering
There’s also the possibility that a customer is in need of a gear as a replacement for an older machine. These machines may not be made, or even serviced any longer, but they still need high-precision gears to function properly. Through reverse engineering, a gear manufacturer can re-create the original gear.
If you’re interested in learning more about how our custom gears keep the world moving, or if you’re in need of a quote for your own custom gear job, be sure to contact us!