There are a wide range of gears out there, and each type serves a specific purpose within an application. Small gears are no different, as they are designed for certain applications where a standard sized gear cannot fit.
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Applications of Small Gears
Some applications of small gears include use in medical devices, tool kits, and exercise equipment or small electronics. They can also be found in applications where large gears are present, such as industrial machinery or in automobiles. Whatever your application may be, consult a small gear manufacturer to ensure you are able to get the perfect small gear for your application. There are a number of different ways to manufacture small gears, each with their own advantages, so make sure you seek out a small gear manufacturer with the capabilities you require.
Manufacturing Process of Small Gears
As stated before, there are a number of different processes used to manufacture gears of all sizes, large and small. Gear forming is perhaps the most common process, as it is used to make large batches of the same shape and size of a single type of gear. The process starts out the same for just about every manufacturer. A mold is made of the desired gear based on customer specifications and requirements. From there, the process can go through a number of different forming methods. Some of these methods include injection molding, casting, forging, roll forming, and quite a few others. Be sure to consult a small gear expert on which type of forming is best for your application. Another part of the process is cutting the gear, which can also be done through a number of different processes such as broaching, shaping, lapping, hobbing, and milling.
Once your gear has gone through the forming and cutting process, it must then go through what is called the finishing process where it will be polished. Again, there are a number of options within this process from grinding to honing and this process is really what sets two gears apart from one another. Generally with small gears, the finishing process takes a bit longer as the gear is often more intricate and requires more precision in order to ensure it is properly finished.