Custom Gears Manufacturer – Made to Drawing & OEM Solutions

Custom Gears Manufacturer – Made to Drawing & OEM Solutions

Transform your technical drawings into precision-engineered gears. From prototype validation to full-scale production, we deliver custom gear solutions with complete transparency—backed by certified inspection reports, flexible material options, and proven heat treatment processes.

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From Prototype to Mass Production

Sample validation, pilot runs, and stable batch delivery under one coordinated workflow.

Material & Heat Treatment Options

20CrMnTi, 42CrMo, 8620H and more, with carburizing, nitriding, and induction hardening.

Inspection Reports Available

Material, tooth profile and lead, hardness, and dimensional reports can be provided with each order.

Lead Time: Prototypes 4-6 weeks | Production 3-5 weeks • MOQ: Prototype accepted | Small batch orders welcome

Custom Gears at wenlio gear

Custom Gear Solutions We Manufacture

Our engineering and production capabilities span the full spectrum of gear types and manufacturing processes. Whether you need a single prototype bevel gear or high-volume helical gear production, we deliver precision components matched to your exact specifications.

Wenlio Precision Straight Bevel Gears

Straight Bevel Gears

Right-angle transmission gears for reducers and gearbox applications, with custom dimensions, heat treatment, and inspection support.

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Wenlio Precision Spiral Bevel Gears

Spiral Bevel Gears

Smooth-running matched sets and custom ratios for applications that need stable meshing, lower vibration, and controlled contact behavior.

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Wenlio precision Hypoid Bevel Gears

Hypoid Bevel Gears

Offset gear sets for higher load capacity, lower noise, and controlled tooth contact in demanding differential and drive applications.

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Wenlio precision Zerol Bevel Gears

Zerol Bevel Gears

Compact right-angle gears that balance easier meshing with more stable contact than a basic straight bevel layout.

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Precision Spur Gear for wenlio gear

Spur Gears

Custom spur gears for industrial transmission systems, OEM replacement work, and drawing-based production with hardening routes.

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Wenlio Helical Gear

Helical Gears

Quieter-running gears for applications that need smoother engagement, controlled lead quality, and repeatable batch production.

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Precision worm gear from wenlio gear

Worm Gears

High-ratio drive components for compact systems where speed reduction, space efficiency, and controlled wear behavior matter.

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precision shaft from wenlio gear

Gear Shafts

Integrated shafts, pinion shafts, and splined shafts produced through turning, hobbing, grinding, and final inspection workflows.

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What We Need for Your Custom Gear Quote

Clear technical documentation ensures accurate quoting and eliminates costly revisions. The more detail you provide upfront, the faster we can validate manufacturability and deliver a comprehensive quotation with lead time and cost breakdown.

Drawing Files

PDF and DWG are required. STEP or IGES files are preferred for complex geometries or assemblies.

Gear Parameters

Include module or diametral pitch, tooth count, pressure angle, helix angle, hand, and requested accuracy standard.

Material Specification

Share the required material grade, such as 20CrMnTi, 42CrMo, 8620H, or accepted alternatives if applicable.

Heat Treatment

Specify carburizing and quenching, nitriding, induction hardening, or other required condition before final inspection.

Surface Treatment

Tell us whether black oxide, plating, rust prevention, or no additional surface treatment is required.

Quantity Plan

Prototype quantity and annual demand help us judge tooling, batching, and the most suitable process route.

Manufacturing Feasibility Analysis (DFM): 

Our engineering team reviews all drawings for manufacturability and can suggest modifications to improve quality, reduce cost, or shorten lead time—at no additional charge.

Send Your Drawing

Process-Driven Manufacturing Capabilities

Our vertically integrated manufacturing process ensures complete control over quality at every stage. From raw material inspection through final packaging, we maintain rigorous process discipline and documentation to deliver consistent, high-precision gears.

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Gear Forging

Forged gear blanks for high-load gears—custom size, fast lead time. Precision gear forging for durable gears; cost-effective and scalable.

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Gear Cutting

CNC hobbing, shaping, and milling for tooth generation. Module range 0.5-12, OD up to 800mm, face width to 300mm.

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Heat Treatment

Carburizing furnaces (gas/vacuum), nitriding, induction hardening.

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Precision Grinding

CNC gear grinding for ISO 1328 Class 5-6 accuracy.

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Quality Inspection

CMM measurement, gear testers (profile/lead/pitch), hardness testing, metallographic analysis. Full dimensional and material reports.

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Packaging & Shipping

Anti-rust treatment, individual wrapping, custom packaging for fragile components. Export documentation and logistics coordination.

Manufacturing Range & Documentation

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Dimensional Capacity

Outside Diameter 5 mm – 800 mm
Module Range 0.5 – 12
Maximum Face Width 100 mm
Precision Grade ISO 1328 Class 5–8
Maximum Helix Angle 45°

Documentation Provided

Material Certificates Mill test reports available
Hardness Reports Surface and core hardness records
Gear Inspection Reports CMM and gear tester data
FAI / PPAP Available upon request
Metallographic Analysis Available upon request

 

Quality Control & Inspection Protocol

Quality is embedded in every step of our manufacturing process, not just inspected at the end. Our three-stage inspection protocol—combined with advanced metrology equipment—ensure every gear meets customer requirements.

Stage 1

Incoming Material Inspection

Raw material is checked mill certificates, with material verification and hardness confirmation before machining begins.

Stage 2

In-Process Quality Checks

First-piece checks, periodic sampling, and process adjustments help maintain drawing requirements during production.

Stage 3

Final Inspection & Testing

Critical features are reviewed by dimensional checks, gear testing, hardness verification, and visual inspection before shipment.

Key Inspection Parameters: 

Tooth Geometry

  • Profile deviation (ffa)
  • Lead deviation (fHβ)
  • Pitch variation (fp)
  • Runout tolerance (Fr)

Material Properties

  • Surface hardness (HRC)
  • Core hardness
  • Effective case depth
  • Microstructure verification

Dimensional Accuracy

  • OD, ID, face width
  • Center distance
  • Surface roughness (Ra)
  • Concentricity & perpendicularity

Inspection Report Samples: We provide anonymized sample inspection reports upon request so you can review our testing methodology and documentation standards before placing an order.

Your Custom Gear Project: From Inquiry to Delivery

A streamlined, transparent process eliminates surprises and keeps your project on schedule. We’ve refined this six-step workflow over hundreds of custom gear projects to balance speed, quality, and cost-effectiveness.

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Confidentiality Agreement (Optional)

For proprietary designs, we’ll execute an NDA before you share technical drawings. Your intellectual property is protected throughout the entire process.

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Drawing Review & DFM Analysis

Our engineering team evaluates manufacturability, identifies potential issues, and suggests cost-saving or quality-improving modifications—typically within 24-48 hours of receiving drawings.

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Quotation & Lead Time Confirmation

Detailed quote including unit price, tooling costs (if any), lead time breakdown, and payment terms. We clarify any assumptions or requirements to prevent scope creep.

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Prototype Production & Inspection

Prototype gears manufactured per your specifications with full dimensional and material inspection. Complete inspection report accompanies prototype samples for your validation.

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Customer Approval & Feedback

Review prototype samples and inspection data. If modifications are needed, we incorporate feedback and produce revised samples until you’re satisfied with the result.

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Mass Production & Shipping

Once approved, we scale to production volumes with the same quality standards. Batch inspection, anti-rust treatment, secure packaging, and logistics coordination to your destination.

Communication at Every Stage: You’ll receive progress updates at key milestones, and our engineering team is available to answer questions throughout the project lifecycle.

Proven Solutions Across Industries

Real-world applications demonstrate our ability to solve complex gear challenges. These anonymized case studies illustrate how our engineering expertise and manufacturing capabilities deliver measurable improvements in performance, reliability, and cost-efficiency.

Electric Outboard Gear

CHALLENGE

The customer needed a quieter helical pinion for an electric reduction gearbox with strict noise targets under load.

SOLUTION

20CrMnTi, optimized carburizing profile, and profile grinding were combined with micro-geometry adjustments.

RESULT

Noise dropped versus the baseline design under the same test conditions while service life expectations were maintained.

Assembly of the components of a three-speed internal gear hub

Agricultural Gearbox Bevel Set

CHALLENGE

A spiral bevel set for heavy-duty agricultural equipment showed premature wear and pitting in field use.

SOLUTION

Material, induction hardening, shot peening, and lapping were adjusted to improve wear behavior and load distribution.

RESULT

Field service life extended and pitting issues were reduced before the project expanded into additional follow-on work.

Explosion diagram of gear pump gear components

Industrial Hydraulic Pump Gear Set

CHALLENGE

The OEM needed stable flow, lower internal leakage, and reduced mesh noise for a compact hydraulic power unit.

SOLUTION

Gear cutting, deburring, controlled heat treatment, and finish grinding were combined with tuned backlash and micro-geometry.

RESULT

Customer testing showed more stable pump performance and the program moved smoothly into full-scale production.

GET SIMILAR SOLUTION FOR YOUR APPLICATION!

Common Questions About Custom Gear Manufacturing

Get answers to the most common questions we receive from engineering and procurement teams. Can’t find what you’re looking for? Contact us directly for project-specific guidance.

What is your minimum order quantity (MOQ)?

We accept prototype orders with no minimum quantity. For production runs, MOQ depends on complexity—typically 50-100 pieces for standard gears, but we’re flexible for specialized applications. Small batch orders are welcome as we understand the need for testing and validation before committing to larger volumes.

What are typical lead times for samples and mass production?

Prototype samples: 4-6 weeks after drawing approval. Mass production: 3-5 weeks depending on quantity and complexity. Rush service available for urgent projects. Lead times include manufacturing, heat treatment, inspection, and preparation of documentation. We provide detailed production schedules with milestone dates upon order confirmation.

Which gear standards do you support?

We manufacture to ISO 1328, DIN 3961, AGMA 2000, JIS B 1702, and customer-specific standards. Our inspection equipment is calibrated to measure according to these standards, and our quality documentation references the applicable standard for your project. We can also work with proprietary company standards if you provide detailed specifications.

Can you help optimize our gear design for manufacturing?

Yes, Design for Manufacturing (DFM) analysis is included at no charge. Our engineering team reviews drawings for manufacturability and can suggest modifications to improve quality, reduce cost, or simplify production.

What inspection reports and documentation can you provide?

Standard documentation includes: dimensional inspection reports (CMM data for critical features), gear inspection reports (profile, lead, pitch measurements), hardness test results (surface and core), and material certificates. Optional documentation available: First Article Inspection (FAI) reports, PPAP packages, metallographic analysis, contact pattern verification for bevel gears, and noise testing data.

What heat treatment options are available?

Carburizing (gas or vacuum), nitriding (gas or plasma), induction hardening, and through-hardening. We can control case depth, core hardness, and surface hardness to your specifications.

How do you handle shipping and packaging?

All gears receive anti-rust treatment (oil coating or VCI wrapping). Individual wrapping or compartmentalized packaging prevents damage during transit. We coordinate international shipping, handle export documentation, and can work with your preferred freight forwarder. For high-value or fragile components, we use custom wooden crates or foam inserts for maximum protection.

What about intellectual property protection?

We sign NDAs as standard practice for proprietary designs. Your drawings and specifications are stored securely with access limited to project team members. We do not reverse-engineer customer products or share technical information with competitors. Many customers have worked with us for years across multiple confidential projects.

Materials & Heat Treatment Expertise

Material selection and heat treatment directly impact gear performance, durability, and cost. Our metallurgical expertise helps you choose the optimal combination for your application requirements—balancing strength, wear resistance, and manufacturability.

Common Gear Materials

  • 20CrMnTi: Carburizing steel for high surface hardness with tough core. Excellent for high-load applications requiring wear resistance.
  • 42CrMo / 4140: Through-hardening alloy steel. Good strength and toughness for medium to heavy-duty applications.
  • 8620H / SCM420: Carburizing grade with superior core strength. Ideal for shock loads and fatigue resistance.
  • 40Cr / 5140: Medium carbon alloy steel for induction hardening. Cost-effective for selective hardening applications.
  • S45C / 1045: Medium carbon steel for lower-stress applications. Can be induction hardened or quenched and tempered.

Heat Treatment Processes

  • Gas Carburizing: Traditional carburizing for general applications. Case depth 0.5-2.0mm, surface hardness 58-62 HRC achievable.
  • Vacuum Carburizing: Cleaner process with minimal distortion and oxidation. Preferred for precision gears requiring minimal grinding stock.
  • Nitriding: Lower temperature process creates hard, wear-resistant surface. Minimal distortion makes it ideal for pre-ground gears.
  • Induction Hardening: Selective hardening of tooth surfaces while maintaining softer core. Fast, cost-effective for certain geometries.

Material Selection Assistance:

Not sure which material or heat treatment to specify? Our engineering team can recommend options based on your load requirements, operating environment, cost targets, and production volumes. We consider factors like contact stress, bending stress, operating temperature, and desired service life to optimize your material selection.

Ready to Start Your Custom Gear Project?

Partner with a manufacturer that combines technical expertise, quality craftsmanship, and responsive service. Whether you need a single prototype or ongoing production support, we’re equipped to deliver precision gears that meet your exact specifications.

20+ Years of Experience

Manufacturing custom gears for OEM and aftermarket applications

800+ Projects Completed

Successful custom gear projects across diverse industries

98% On-Time Delivery

Meeting committed lead times and quality standards consistently

Get Started Today

Send your technical drawings and specifications to receive a detailed quotation with lead time estimate. Our engineering team will review your requirements and respond within 24-48 hours with any questions or recommendations.

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