Custom-Manufactured Gears
Not every machine power transmission system can be designed using standard gears. Applications involving special dimensions, unique tooth geometries, non-standard connections, or replacement parts that are no longer commercially available may require custom manufacturing. At Erdişli Makina, we provide custom gear manufacturing solutions for various industries, backed by our experience in gear and machine spare-part production since 1987. We manufacture gears for new projects according to technical drawings and can also reproduce existing, worn, or damaged gears by evaluating them as samples. With manufacturing capabilities ranging from Ø20 mm to Ø1300 mm, we produce custom components across a broad range of sizes, from small machine parts to large industrial gears. A custom-manufactured gear is specifically produced for a particular machine or project when standard commercially available products cannot meet the required dimensions, material specifications, tooth geometry, or connection requirements. Even a modification to the diameter of a standard gear may require custom manufacturing, while components with entirely different tooth geometries, hub designs, shaft connections, or materials can also be produced. The objective of custom gear manufacturing is to create a reliable power transmission component that accurately fits the existing system and meets its specific operating requirements. At Erdişli Makina, we evaluate the complete technical requirements of each application when manufacturing custom gears. Depending on the component, parameters such as the following can be evaluated: Gear type Module Number of teeth Tooth geometry Pressure angle Helix angle and direction Outside diameter Face width Hub dimensions Shaft bore Keyway Material Heat treatment Operating speed Transmitted torque Mating gear specifications This enables us to provide application-specific solutions for machinery and mechanisms where standard catalog products are insufficient. Components with available technical drawings can be manufactured according to the dimensions and technical specifications indicated in the drawings. Tooth geometry, tolerances, material specifications, hub design, bores, grooves, and other details shown in the technical drawing form the basis of the manufacturing process. This manufacturing method is particularly suitable for: New machinery projects Machine manufacturers R&D projects Prototype production Industrial facilities Maintenance teams Overhaul projects Not every replacement component has an available technical drawing. Particularly in machinery that has been in operation for many years, technical documentation may have been lost, the original manufacturer may no longer be in business, or original replacement parts for imported machinery may no longer be available. In such cases, the existing gear can be evaluated as a sample to determine the required dimensions and technical specifications. Parameters that can be evaluated from the sample include: Gear type Module Number of teeth Tooth geometry Face width External and internal dimensions Hub design Shaft bore Keyway Material properties These parameters can then be used to manufacture a replacement component. Where possible, examining the mating component of the sample gear can also help evaluate overall system compatibility. Industrial machinery can have a very long economic service life. However, while the machine itself may remain operational, its manufacturer may discontinue certain replacement components. In such situations, even a relatively small gear failure can prevent a large machine or an entire production line from operating. Determining the technical specifications of the existing component and reproducing it can provide an alternative to replacing the entire mechanism or machine. At Erdişli Makina, we provide solutions particularly for the reproduction of machine gears that are no longer commercially available, have been discontinued, or are difficult to source, using existing components as samples. Long lead times and difficulties in sourcing original replacement components for imported machinery can result in significant production losses. Where technically feasible, the required gear can be manufactured locally using an existing component as a sample or according to its technical drawing. This approach can provide an important alternative for replacement gears used in: Production machinery Packaging machinery Textile machinery Food processing machinery Agricultural machinery Conveyor systems Gearboxes Metalworking machinery Specialized industrial equipment Depending on project requirements, we manufacture various types of custom gears and power transmission components. Our manufacturing capabilities include: Spur gears Helical gears Bevel gears Chain sprockets Timing pulleys Worms and worm gears Bronze gears Cast polyamide gears Rack gears Pinion gears Gear shafts Custom-geometry machine gears The specifications of each gear are determined according to the technical requirements of the application. Gear dimensions required by different machinery and industries can vary significantly. Within our manufacturing capabilities, Erdişli Makina produces gears ranging from a minimum diameter of Ø20 mm to a maximum diameter of Ø1300 mm. This broad manufacturing range enables us to meet requirements ranging from gears used in small mechanical systems to large industrial machine components. Selecting the correct material for a custom gear is critical to its operating performance and service life. Depending on application requirements, materials can include: 4140 8620 1040 17CrNiMo6 Bronze Cast Polyamide Aluminum Other materials suitable for specific project requirements can also be evaluated. Material selection should take into account factors such as operating load, rotational speed, impact conditions, operating temperature, mating gear specifications, and the operating environment. For gears operating continuously or under high loads, increased wear resistance of the tooth surfaces may be required. Depending on the material and application requirements, heat treatment processes such as carburizing, induction hardening, and nitriding can be evaluated. An appropriate combination of material and heat treatment can help achieve surface properties suitable for the operating conditions and extend the service life of the component. Custom gear manufacturing involves more than machining the gear teeth. Depending on how the gear is connected within the machine, additional mechanical features may include: Custom shaft bores Keyways Hubs Flanges Mounting holes Stepped diameters Custom grooves and recesses These features can be evaluated according to technical drawings or existing samples and incorporated into the manufacturing process. Gears operating over long periods may experience wear, broken teeth, deformation, or other forms of mechanical damage. When reproducing a damaged gear, simply copying its existing dimensions may not always be sufficient. Worn tooth surfaces may no longer accurately represent the original geometry of the component. For this reason, whenever possible, the mating gear, operating conditions, and position of the component within the system should also be evaluated. The objective is not simply to create a physical copy of the existing component, but to manufacture a replacement gear capable of operating correctly within the system. A reliable custom gear requires multiple technical parameters to be evaluated together. Key considerations include: Tooth geometry Module Number of teeth Pressure angle Helix specifications Operating speed Transmitted torque Material Heat treatment Mating gear specifications Center distance Shaft and hub connection Lubrication conditions Operating temperature Operating environment Particularly in heavy-duty applications, proper material selection, tooth geometry, and heat treatment are important factors affecting component service life. Custom gear manufacturing plays an important role not only in new machinery projects but also in maintenance and overhaul operations for existing equipment. When a gear in a production line becomes damaged, the unavailability of the original replacement component can result in extended machine downtime. Custom manufacturing based on technical drawings or existing samples can provide a solution for reproducing the required spare part and returning the system to operation. Custom gears can be used across a wide variety of industries and machinery systems. Typical applications include: Machinery manufacturing Industrial gearboxes Production lines Iron and steel industry Metalworking machinery Conveyor and material handling systems Agricultural machinery Food processing machinery Packaging machinery Textile machinery Automation systems Lifting and handling equipment Maintenance and overhaul applications Custom machinery projects At Erdişli Makina, we provide custom gear and machine spare-part manufacturing solutions for customers in Türkiye and international markets. Manufacturing requests can be evaluated based on technical drawings or existing sample components. From new machinery projects to single replacement-part requirements, we aim to provide manufacturing solutions tailored to a wide range of industrial needs. We combine our experience in gear and machine spare-part manufacturing since 1987 with the custom manufacturing requirements of today's industrial sector. With a manufacturing range of Ø20 mm to Ø1300 mm, various material options, and the capability to manufacture according to technical drawings or existing samples, we provide custom solutions for gear requirements that cannot be met by standard products. Whether the requirement involves a new machinery project, a discontinued replacement part, a gear for imported equipment, or maintenance of machinery that has been operating for many years, we evaluate the component's technical specifications and operating conditions to determine an appropriate manufacturing solution. For custom gear manufacturing, gear production from technical drawings, gear reproduction from samples, or discontinued machine spare parts, contact Erdişli Makina.Custom Gear Manufacturing for Your Machinery and Projects
What Is a Custom-Manufactured Gear?
Erdişli Custom Gear Manufacturing
Gear Manufacturing from Technical Drawings
Gear Manufacturing from Samples
Reproduction of Discontinued Spare Parts
Replacement Gear Manufacturing for Imported Machinery
Types of Custom Gears We Manufacture
Manufacturing from Ø20 mm to Ø1300 mm
Material Options
Heat Treatment Options
Custom Connection and Machining Details
Reproduction of Worn or Broken Gears
What Should Be Considered in Custom Gear Manufacturing?
Custom Manufacturing for Maintenance and Overhaul Projects
Applications of Custom-Manufactured Gears
Custom Gear Manufacturing for Domestic and International Customers
Why Erdişli Makina?