Product Specifications
|
Specification |
Available Range / Standard |
|
Gear Types |
Spur, helical, bevel, worm, and small-module gears |
|
Module Range |
0.5-3.0 |
|
Number Of Teeth |
12-120 teeth |
|
Standard Pressure Angle |
20° |
|
Precision Grade |
JIS B 1702-1 Grade N9-N12 |
|
Dimensional Tolerance |
±0.05 mm |
|
Backlash Range |
0-0.60 mm |
|
Bore Diameter |
2-30 mm |
|
Face Width |
3-30 mm |
|
Materials |
POM, PA / nylon, reinforced PA66, PBT, and PPS |
|
Shaft Interface |
Round bore, D-bore, spline, keyway, press-fit hub, metal shaft, or insert-molded bushing |
|
Gear Inspection |
Tooth profile, pitch diameter, bore, face width, runout, concentricity, and double-flank rolling check |
Key Features
● Controlled Tooth Profile, Runout, And Backlash
The cavity and shrinkage allowance are set from the specified module, pressure angle, tooth count, center distance, and mating gear. In low-speed actuators and high-cycle gear trains, controlled concentricity and backlash help prevent binding, irregular rotation, vibration, and tonal gear noise.
● Material Selection For Load And Environment
POM is commonly used for low friction and dimensional stability in dry, low-noise mechanisms. PA66 and reinforced nylon suit higher loads and impact, while PBT, PPS, and other engineering resins are options for greater heat or chemical exposure. Resin selection is based on speed, torque, humidity, and temperature to limit dimensional drift and early tooth wear.
● Integrated Hub And Shaft Connection
Splines, D-shaped bores, press-fit hubs, molded bearings, lubrication grooves, and metal shaft or bushing inserts can be molded into the gear. This integrated connection carries reversing torque and repeated start-stop loads without a separate adhesive or post-assembly operation.
Customization Options
● Gear Geometry
Customize the gear type, tooth data, and center-distance relationship to match the mating transmission.
● Material And Performance
Select the resin and reinforcement according to torque, speed, temperature, and friction conditions.
● Hub And Shaft Interface
Define the bore, hub, and optional shaft or bushing insert for the required torque transfer.
Customization Process
Requirement Confirmation
Confirm the mating gear, torque and speed range, and operating duty cycle.
Engineering Review
Set the tooth correction, backlash allowance, and hub-strength criteria before tooling.
Mold Design And Manufacturing
Machine the cavity to control tooth profile, concentricity, and stable filling of the rim and hub.
Trial Molding And Sample Approval
Test trial gears in the intended assembly and approve meshing, runout, and bore fit.
Production And Inspection
Monitor material condition, molding stability, and tooth or bore defects during production.
Packing And Delivery
Separate the gears to prevent tooth contact and deformation, with lot identification on each package.
Quality Control
● Process Stability
Material moisture, melt temperature, mold temperature, cooling time, and cavity condition are recorded and controlled. Changes in any of these items can affect shrinkage, pitch, bore size, and tooth form.
● Gear-Specific Measurement
Inspection follows the drawing and covers outside diameter, root diameter, bore, face width, runout, concentricity, and tooth profile. Functional mesh or double-flank rolling inspection is added when the control plan requires it.
● Appearance And Batch Release
Each batch is checked for flash on tooth flanks, short shots, burns, voids, deformation, contamination, and damaged hubs. Release is based on the approved sample and the corresponding inspection records.
FAQ
Q1: Can a sample be supplied before production?
A1: Basic reference samples are available when stock permits. A custom gear sample requires an approved drawing or physical sample, confirmed mating conditions, and advance payment of the mold-development cost.
Q2: How long does custom sample development take?
A2: Mold-based sample development normally takes 40–60 days after the structure, material, gear data, and tooling plan are approved. Gear complexity, insert requirements, and the number of trial adjustments can change the schedule.
Q3: Can you reproduce a gear that must mesh with an existing part?
A3: Yes. Send the existing gear or accurate data for module or diametral pitch, tooth count, pressure angle, center distance, bore position, rotation direction, and allowable backlash. A functional assembly sample is preferred for final validation.
Q4: Can a metal shaft or bushing be molded into the gear?
A4: Yes. A prepared metal shaft or bushing can be insert-molded into the gear. Engineering review must confirm its material, surface condition, retention geometry, concentricity, and compatibility with the molding temperature.
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