gear manufacturer

High-quality Custom Gear Manufacturer

Federal Gear and Machine has been cutting teeth since 1914, making us a trusted source for components in a wide range of industries and applications. Whether you need one gear or one thousand gears, our team of experienced professionals can cut, machine, and manufacture custom solutions for your unique project.

Our Gearing Capabilities

Spur Gears

We manufacture spur gears from .25 to 96DP (25.4 to .26 MOD) with quality levels up to AGMA 9. Available sizes range from ¼” to 96” OD, and overall lengths up to 80″.

Spur gears have straight teeth and are the most common type of gear. They are used to transmit motion between two parallel shafts and are known for being highly efficient and producing a lot of power. Depending on the application, they can be mated with a rack, another spur gear, or an internal gear.

Helical Gears

We manufacture helical gears from .25 to 96DP (25.4 to .26 MOD) with quality levels up to AGMA 9. Available sizes range from ¼” to 96” OD, and overall lengths up to 80″.

Helical gears have teeth that are “twisted” or set on an angle to the gear axis. The features and benefits are similar to spur gears but can be a better option when higher velocities are needed. Helical Gears can be produced in a right hand or left-hand configuration or as mates in pairs consisting of one right hand and one left hand gear with the same helix angle. They helix angle creates more tooth contact between the gears resulting in more of a sliding motion the yields quieter, smoother operation.

Shafts and Splines

Federal Gear and Machine specializes in cutting large shafts, up to 80 inches in length (with up to 135-inch faces and 40-inch OD), with splines or involute teeth. Standard and Metric sizes available.

Splines are used to connect two parts together. Unlike gears they are not usually used to transmit motions. The external teeth on a shaft mesh with the internal teeth of the mating part allowing torque to transfer from one piece to another.

Internal Gears

We cut internal gears, splines or sprockets from 1DP to 96DP (25.4 to .26 MOD), and blanks of up to 40 inches OD with gear faces of up to 17 inches in length. We can also shape, or mill stacked gears and other specialty applications where hobbing is not viable.

Worm and Worm Gears

We cut, heat treat, straighten, and grind multiple thread ground worms, with up to 40 inches of length and 12 inches of outside diameter. We also manufacture worm gears with up to two-inch CP and 30-inch OD without the need for special tooling. Our ability to model and mill the worm gear eliminates the need for special tooling and long lead times.

Worms and worm gears sets are used to transmit motion between nonparallel shafts. Worms can be single or multithreaded and look like large screws. A worm gear system consists of a worm and worm wheel positioned as a cross axis and is the most compact type of gear system. The worm is paired with a worm gear, that looks similar to a spur gear. Worm gears systems are compact, offer large gear reductions and large speed reductions. Due to the compact design, worm gear reducers are able to be placed in relatively small spaces and provide high-ratio speed reduction. Worm gears are known to run smoothly and quietly, as long as they are properly mounted and lubricated.

Bevel Gears

Federal Gear and Machine is a leading manufacturer of the highest quality bevel gears. Available in sizes from 1.5 DP and outside diameters of up to 48 inches. Standard and Metric sizes available.

Bevel gears are cone shaped gears designed to transmit motion between intersecting axes. They are usually mounted on shafts that are 90 degrees apart but can be designed for nearly any angle. There are several types of bevel gears including straight, spiral, zerol and hypoid. The choice of gear is dependent on the requirements of the application.

Sprockets

Our ability to hob, shape, EDM or mill sprockets provides allow us to manufacture or reverse engineer almost any custom sprocket request.

Sprockets are profiled wheels with teeth that mesh with a perforated material to create a reliable drive system. They can be used to transmit power, timing purposes or moving materials (conveyors). Sprockets are used in bicycles, film projectors and tanks. They are known for being a dependable drive system for continuous drive applications providing the maximum absorption of shock and minimum torque load.

Capabilities


PRODUCTS DP MAX MAX OD FACE MAX
Spur and Helical Gears 0.25 96" 40"
Spline and Shafting 1 40" 40"
Worms 1.25 CP 12" 48"
Worm Gears 2.00 CP 30” 12"
Herringbone & Double Helical .05 30" 36"
Straight Bevel 1.5 DP 48”
Internal Keyway 3" Wide 50" 25"
Internal Spline 1 DP 33" 16"
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