Hansheng Automation (Dongguan) Co., Ltd. is one of the most experienced manufacturers and suppliers of custom helical gears in China. If you're going to wholesale bulk cost-effective custom helical gears made in China, welcome to get pricelist and quotation from our factory. Also, customized service and OEM&ODM service are available.
As a leading gear manufacturing OEM partner in China, Hansheng provides a diverse range of customized gear solutions. With ten years of technical experience in manufacturing high-precision planetary gearboxes (P0) and harmonic reducers, our gears feature excellent design, smooth meshing, quiet operation, and superior load distribution.
Why Choose Our Custom Helical Gears?
Scalable Precision for Your Budget
We don't force you into over-paying for unnecessary precision. Whether you need ultra-precise ISO 5 (AGMA 11) for robotic joints or cost-effective ISO 7-9 for general industrial machinery, we tailor the manufacturing process to meet your exact blueprint and budget.
Advanced Hard Skiving (Kashifuji KPS30)
Powered by our Kashifuji KPS30 equipment, our hard skiving process replaces traditional grinding for many applications. This eliminates heat-treatment distortion, delivers exceptional surface finish (Ra 0.4), and reduces your lead time by up to 30%.
Optimized for Whisper-Quiet Operation
By utilizing precise helix angles and advanced tooth modifications (like crowning and tip relief), our helical gears achieve an optimized contact ratio via precise helix angles and tooth modifications (e.g., crowning and tip relief), which substantially mitigate vibration and noise – a critical feature for EV and medical device applications
End-to-End Quality Transparency
Every custom gear batch can be accompanied by comprehensive documentation, including material certificates, heat treatment reports, and CMM gear inspection charts. You get exactly what you specified.
Technical Specifications for Precision Helical Gears
We specialize in high-precision, small-to-medium-sized gears. Below are our standard manufacturing parameters.
| Parameter | Specification / Range |
| Precision Grade |
Up to ISO/DIN 5 (AGMA 11) for high-end applications. ISO 6 - ISO 9 available for standard industrial & cost-effective needs. |
| Module Range (M) | M0.5 – M5 |
| Outer Diameter (OD) | 3 mm – 300 mm |
| Helix Angle | Up to ±45° (Left-hand or Right-hand available) |
| Common Materials | Alloy Steel (20CrMnTi, 8620, 42CrMo4, 18CrNiMo7-6), Carbon Steel, Stainless Steel, Brass, Custom Alloys |
| Heat Treatment | Carburizing & Quenching , High-Frequency Induction , Nitriding |
| Surface Hardness | HRC 58 – 62 (Post-heat treatment, customizable) |
| Manufacturing Process | Hobbing, Shaping, Hard Skiving (Kashifuji KPS30), Gear Grinding |
| Surface Roughness |
Ra 0.4 - Ra 0.8 (Skived / Ground) Ra 1.6 - Ra 3.2 (Hobbed / Milled) |
| Tooth Modification | Crowning , Tip Relief (EV & Robotics highly demand this) |
| Inspection Equipment | CMM , CNC Gear Measuring Center, Hardness Tester |
| Reports Provided | Material Certificate, Heat Treatment Report, Gear Inspection Chart (Lead/Profile test reports) |
Inside Our Factory: The Step-by-Step Machining Process of Custom Helical Gears
Let us take our case of custom helical gears (18CrNiMo7‑6 / EN 1.6587 alloy steel) for high‑torque robots as an example to illustrate our processing flow. To protect customer privacy, all relevant parameters and specifications have been adjusted.
We begin with premium 18CrNiMo7‑6 alloy steel bars, chosen for their exceptional core toughness and fatigue resistance. Every raw bar undergoes ultrasonic testing (UT) to verify the absence of internal micro‑cracks before being cut to precise lengths on automated band saws.
The blank is mounted on our precision CNC lathes to establish the initial outer diameter (OD), inner bore, and reference faces. At this stage, we leave a strict pre‑machining allowance of 0.2 – 0.5 mm (adjusted according to the gear module and geometry) to compensate for subsequent heat‑treatment distortion.
Using high‑speed CNC gear hobbing machines, we cut the initial helical teeth. Since the material is still in its "soft" (pre‑hardened) state, we focus on generating the precise helix angle while leaving sufficient grinding/skiving stock on the tooth flanks.
The "green" gears are sent to our controlled‑atmosphere furnaces. Through carburizing and quenching, the surface hardness is raised to a robust HRC 58–62 for maximum wear resistance, while the core remains ductile (around HRC 35–40) to absorb shock loads. Immediately after quenching, a low‑temperature tempering cycle is applied to relieve residual stresses and stabilise the microstructure.
(Optional additional step – Shot Peening: After tempering, we can apply a controlled shot‑peening process to the tooth roots and flanks, further increasing fatigue strength and resistance to micropitting.)
Heat treatment inevitably causes slight warping. We use hard turning (with CBN tooling) to true up the mounting bore and locating faces, ensuring perfect concentricity and minimising runout before the final tooth profiling.
To achieve ISO 5 precision, we combine two complementary processes:
Hard skiving efficiently removes the bulk of the remaining hardened stock while correcting heat‑treatment distortions.
Gear grinding then performs the final finishing pass, eliminating any thermal marks, applying necessary tooth modifications (e.g., crowning), and delivering a mirror‑like surface roughness of Ra 0.4 – all with the repeatability required for high‑grade gears.
Every batch passes through our gear measuring centre, where comprehensive reports are generated for involute profile, lead angle, and pitch deviation. Finally, Magnetic Particle Inspection (MPI) verifies that no grinding burns or cracks remain on the tooth surfaces, guaranteeing zero defects before delivery.
Our Process
Consultation & Design
Whether you have a ready-made CAD file or just a concept, our engineers can assist with gear geometry optimization to minimize backlash and wear.
Precision Machining
Utilizing CNC Gear Hobbing and Skiving machines, we cut the teeth with exacting standards.
Heat Treatment
Enhancing mechanical properties to match your operational environment.
Finishing
Precision grinding or hard skiving to achieve the final profile and surface finish (Ra 0.4 or better).
Quality Assurance
Every batch undergoes rigorous inspection using our advanced Gear Inspection Machines. We provide Lead, Profile, and Pitch error charts with every shipment.
Applications
Our ISO 5 Ground Gears are trusted in industries where failure is not an option:
Robotics & Automation: Joint modules, robotic arms, and pick-and-place machines requiring zero or low backlash.
Medical Devices: Surgical robots, imaging equipment, and laboratory centrifuges.
Automotive & EV: Transmission components and electric actuation systems.
Machine Tools: Spindle drives and high-precision positioning tables.
Ready to Elevate Your Machine's Performance?
Don't compromise on the most critical component of your drivetrain. Partner with a manufacturer who understands precision down to the arc-second.
We protect your IP: We are happy to sign a Non-Disclosure Agreement (NDA) before reviewing your proprietary designs.
Click here to submit your inquiry. Our engineering team will review your requirements and provide a detailed DFM (Design for Manufacturing) report and quotation within 24 hours.
FAQ
Q: What precision levels can you achieve for custom helical gears?
A: We standardly achieve ISO/DIN Grade 5 (equivalent to JIS Grade N5 or AGMA 11-12). Thanks to our advanced Kashifuji KPS30 Gear Skiving Machine, we can maintain this high precision even after heat treatment using "Hard Skiving" technology. Our capability is proven by our internal production of Harmonic Drives (backlash ≤10 arc sec) and Planetary Gearboxes (backlash ≤1 arc min).
Q: How do you handle gear distortion after heat treatment?
A: Heat treatment often causes gear teeth to deform. Unlike traditional shops that only use hobbing (which cannot correct hardened gears), we utilize Hard Skiving and Precision Grinding capabilities. This allows us to machine the gear teeth after they are hardened, correcting any distortion to ensure perfect tooth profile, pitch accuracy, and low-noise operation.
Q: What is your minimum order quantity (MOQ)? Do you accept prototype orders?
A: Our minimum order quantity is 5 pieces. But our service is very flexible, and we also support prototypes to help you validate your design. Although the unit cost of mass production (such as 50 or more pieces) is more advantageous, we are fully capable of handling single sample orders for our B2B partners.
Q: What quality documentation do you provide with the shipment?
A: Every shipment includes a comprehensive Dimensional Inspection Report and material certificates. For gear accuracy, we provide detailed charts showing Profile Error, Lead Error, and Pitch Error, generated by our dedicated Gear Inspection Machines.
Q: What file formats do you need for a quotation?
A: For the most accurate quote, please provide:
3D Models: STEP (.stp) or IGS (.igs) files.
2D Drawings: PDF files specifying critical tolerances, materials, heat treatment hardness (HRC), and accuracy class requirements.
Note: We are happy to sign an NDA (Non-Disclosure Agreement) before receiving your files to protect your intellectual property.
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