Description

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Fine-pitch gear components engineered for high-ratio micro-gearboxes, optical positioners, and closed-loop actuator assemblies. Produced via precision gear hobbing, micro-shaping, or 5-axis micromachining depending on geometry and batch volume. Supplied with full Material Test Reports (MTR) and analytical gear rolling/inspection charts.

Technical Specifications

Parameter	Standard / Range	Verification Method
Module (m) / DP	m = 0.1 ~ 1.0 / DP 48 ~ 250	Optical Comparator / Gear Checker
Precision Grade	DIN 5 to DIN 8 (AGMA Q10 to Q14)	Gleason/Klingelnberg Analytical Gear Tester
Pressure Angle (alpha)	20° (standard), 14.5°, custom angles	Profile Meter
Pitch Diameter Tolerance	+/- 0.005 mm to +/- 0.015 mm	3D CMM / Micrometer
Total Indicated Runout (TIR)	<= 0.008 mm (bore-to-pitch circle)	Air Gauge / Arbor Inspection
Backlash (Assembled pair)	0.010 ~ 0.035 mm (center-distance dependent)	Double-Flank Roll Tester
Surface Finish (Tooth flank)	Ra 0.4 ~ 0.8 um	Surface Roughness Tester

Standard Material Matrix

Ferrous: AISI 303 / 304, AISI 17-4PH (H900/H1025 condition), 4140 (through/induction hardened to 48–52 HRC).

Non-Ferrous: C3604 Free-machining brass, Ampco bronze.

Engineering Plastics: Acetal (POM-C), PEEK (unfilled or carbon-filled), Nylon PA66-GF30.

Key Features

Controlled Tooth-Root Undercut: Finite-element profile shift modification applied for pinion-gear pairs with tooth count z < 13.

Micro-Burr Elimination: Electrochemical deburring (ECD) or low-media centrifugal tumbling preventing micro-root stress risers and debris ingress in sealed gearboxes.

Bore-to-Datum Concentricity: Inner diameter honed or hard-turned in a single chucking setup relative to the pitch circle reference diameter.

Lot-to-Lot Involute Profile Consistency: CNC hobbing synchronized with thermal-stabilized shop environment (+/- 1°C).

Applications

Robotics: Harmonic/Cycloidal micro-reducer stage inputs, encoder drive gear trains.

Medical: Surgical stapler internal multi-stage torque transfer, infusion pump rotary escapements.

Optics & Photonics: Motorized zoom-lens cam-follower gear rings, LIDAR scanner mirror drive trains.

Metrology: Dial indicator multiplier trains, optical rotary encoder reduction gears.

Customization Capabilities

Dimension	Custom Scope	Tooling / Lead Impact
Geometry	Spur, helical (up to 15°), worm & worm wheel, cluster gears	Non-standard hob: +2–3 weeks (if pitch unlisted)
Bore / Hub	D-bore, splined, set-screw flat, integrated pinion shaft, snap-ring groove	Standard broach/milling: No extra lead time
Surface Treatment	Black oxide, electroless nickel (EN), passivation (ASTM A967), DLC coating	+3–5 business days
Non-Destructive Test (NDT)	100% magnetic particle or fluorescent penetrant for aerospace grades	Per customer inspection plan (CIP)

Manufacturing & Quality Control

Machining Assets: 12 CNC high-precision gear hobbers (Module 0.1 capable), 4-axis/5-axis CNC micromachining centers, Swiss-type turning centers for integrated shaft-pinions.

Inspection Flow:
• Incoming raw material: PMI (Positive Material Identification) + Hardness coupon check.
• In-process: First-article inspection (FAI) per AS9102 / customer PPAP Level 3 format; 1-in-20 rolling test.
• Final QC: Analytical gear measurement (involute profile Fa, helix deviation Fh, total cumulative pitch deviation Fp), sampling AQL 0.65 or 100% inspection for critical safety parts.

Packaging & Logistics

Packaging Architecture: Individual anti-static/anti-corrosion VCI blister trays or compartmentalized ESD foam nests. Zero tooth-on-tooth contact during transit.

Documentation Pack: Packing slip, CoC (Certificate of Conformance), MTRs, Gear rolling inspection summary plot, RoHS/REACH declaration.

Incoterms: FOB Shanghai/Ningbo or DDP via DHL/FedEx Express (for prototypes) / Air Freight (volume).

Frequently Asked Questions

Q: What is your minimum order quantity (MOQ) for custom fine-pitch module 0.3 gears?

A: Prototypes: 10–50 pcs (setup/tooling cost itemized or amortized). Production: MOQ typically 500 pcs/batch. Lower volumes evaluated case-by-case if shared with running production schedules.

Q: Can you work from a STEP file alone, or do you require 2D GD&T?

A: STEP file defines 3D envelope and interface, but manufacturing and QA require 2D drawing specifying datum structures (A/B/C), precision grade (DIN/AGMA), and maximum allowable backlash at designated center distance. If GD&T is missing, our engineering drafts a control drawing for customer sign-off.

Q: How do you handle non-standard fine-pitch hob procurement?

A: If standard m=0.25 or DP 120 cutters are off-shelf, lead time is standard machining (2~3 weeks). Custom profile modifications require custom carbide hob generation (3~4 weeks tool lead time, charged at cost or amortized over 2,000+ units).

Q: What evidence proves batch-to-batch runout consistency?

A: Every production lot includes a statistical process control (SPC) chart for key inspection characteristics (TIR and base diameter) and a sample rolling test graph. Full PPAP Level 3 package available upon contractual agreement.

Q: How are non-standard hob/cutter tooling costs handled if the design changes post-prototype?

A: Standard practice: Tooling cost is itemized on the FAI invoice ($150–$350 per custom fine-pitch hob). Physical or optical profile comparison report is provided with the tool acceptance sign-off. Tool remains dedicated to your part number. (DFARS / ITAR: Standard commercial/industrial grade; defense-cleared DFARS material sourcing available upon request for aerospace RFQs).

Interactive RFQ Portal & Technical Check-In

Dropzone Config: Drag-and-drop zone accepting .STEP, .PDF (GD&T), .DXF | Max limit: 50MB/file | Auto-generates tracking hash/ticket upon drop (e.g., Ticket #GEAR-88XX).

Required RFQ Parameters Checklist:

CAD & Control Drawing: Upload STEP + PDF (explicit DIN/AGMA grade, bore tolerance, datum references).

Operating Parameters: Speed (RPM), torque load (Nm or Ncm), lubrication regime (grease/oil/dry), ambient temp (T).

Volume Projections: Prototype quantity (10–50 pcs, 10-day SLA) + Annual projected volume (EAU).

Compliance Tier: Commercial standard / MTR trace / DFARS aerospace compliance.

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Fine-Pitch Gears