Gear Manufacturing

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Excellence in Gear Manufacturing

At Aerostar Global Manufacturing, we are your trusted partner for high quality gear solutions that power industries around the world. With a commitment to excellence and innovation, we deliver precision engineered gears that meet the most demanding specifications and performance requirements.

At Aerostar Manufacturing, gears are more than mechanical components—they are the driving force behind progress. With precision engineering, cutting edge technology, and unwavering dedication, we continue to shape industries and empower innovation.

Our team of experienced engineers utilizes the latest design software and techniques to develop custom gear solutions tailored to your specific applications.

With state of the art machinery and advanced manufacturing processes, we produce gears with unparalleled accuracy and consistency, ensuring optimal performance and reliability.

Gear Manufacturing Process

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Design and Engineering

Engineers analyze the requirements and specifications provided by the client. This involves determining the gear type, size, tooth profile, material, and other critical parameters. Advanced CAD (Computer-Aided Design) software is used to create detailed drawings and models of the gear.

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Material Selection

The appropriate material for the gear is selected after the design is finalized based on factors such as strength, wear resistance, and operating conditions. Common materials used for gears include steel, cast iron, brass, and various alloys.

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The selected material is cut into the rough shape of the gear blank using processes such as sawing, shearing, or punching. The blank is typically oversized to allow for subsequent machining operations.

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The gear blank undergoes various machining operations to achieve the final shape and dimensions. This includes processes such as turning, milling, drilling, and boring, which are performed using CNC (Computer Numerical Control) machines for high precision and accuracy. The gear teeth are typically cut using gear hobbing or gear shaping machines, which utilize specially designed cutting tools to create the desired tooth profile.

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Heat Treatment

The gear undergoes heat treatment after machining to improve its mechanical properties. This typically involves processes such as carburizing, quenching, and tempering, which enhance the hardness, strength, and wear resistance of the gear. Heat treatment also helps relieve internal stresses induced during machining.

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Gears may undergo grinding operations to achieve critical tolerances and superior surface finishes. It is a precision machining process that removes material from the gear teeth using abrasive grinding wheels. This step is critical for achieving smooth operation and reducing noise and vibration in the gear system.

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Finishing & Inspection

The gear undergoes finishing operations to remove any remaining burrs or imperfections and achieve the desired surface finish after machining, heat treatig, and grinding. The gear is thoroughly inspected using precision measuring instruments such as CMMs (Coordinate Measuring Machines), gear testers, and optical comparators to ensure that it meets the specified requirements and tolerances.

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Assembly & Testing

The finished gear may be assembled into the gear system and undergo functional testing to verify its performance under operating conditions. This may involve running the gear system at various speeds and loads to ensure smooth operation, proper meshing of teeth, and minimal backlash.

Industries & Applications

Our gears are used in a wide range of industries, including:

Aerospace & Defense


Industrial Machinery



Oil & Gas

Power Generation

Marine & Offshore

Electric Vehicle


Material Handling

Case Studies

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