Custom Gear Manufacturing for Industrial Applications
TOP NOTCH GEAR is a full-capability gear manufacturing company. We cut custom industrial gears from raw blank to finished, heat-treated, inspected, and shipped — in-house. We make gears for our own gearbox rebuilds, and we make gears for plants, OEMs, and industrial customers who need replacement, upgrade, or obsolete gearing on rush turnaround.
Gear Types We Manufacture
- Spur Gears — External and internal, any module, any pitch.
- Helical Gears — Single and double helical (herringbone), left and right hand.
- Bevel Gears — Straight, spiral, and Zerol bevels for right-angle drives.
- Worm Gears & Worms — Single, double, and quadruple thread.
- Sprockets, Pinions, and Racks — Custom and replacement.
- Splined Shafts & Couplings — Internal and external splines, custom shaft assemblies.
- Specialty Gearing — Non-standard tooth forms, custom modifications, and obsolete designs.
In-House Gear Cutting & Finishing Capabilities
- Gear hobbing — high-capacity for large industrial gears
- Gear shaping for internal gears and shouldered configurations
- Gear grinding for precision finishing and noise reduction
- Gear broaching for splines and internal forms
- CNC turning and milling for blank preparation
- Heat treatment, carburizing, induction hardening, and case hardening
- Finish grinding, lapping, and inspection
- AGMA quality inspection and documentation
Materials We Work With
We manufacture gears from a wide range of industrial materials — alloy steels (4140, 4340, 8620, 9310), carbon steels, stainless, bronze (for worm gears), cast iron, and specialty alloys as required by the application. Material selection is engineered against the load, environment, and life expectations of the application.
Reverse Engineering & Obsolete Gear Manufacturing
When a gear has failed and the OEM no longer supports the equipment — or never did — we reverse-engineer the part from the failed component, mating gear, drawings, or measurements. This is one of the most valuable services we provide to plants running legacy equipment that is still critical to production. Learn more about our reverse engineering service →
Rush Gear Manufacturing for Emergencies
When a plant cannot wait the standard OEM lead time for replacement gearing, our shop can prioritize critical-path gear cutting on rush schedule. Call our 24/7 emergency hotline to discuss rush manufacturing of a critical gear.
Quality, Inspection & Documentation
Every gear we manufacture is inspected to AGMA standards and ships with documentation that supports your reliability and quality program. We provide material certs, heat treatment records, dimensional inspection reports, and gear quality data.
Frequently Asked Questions
Can you manufacture a single replacement gear, or do I need to order in quantity?+
We manufacture single gears all the time. There is no minimum quantity — most of our gear manufacturing work is one-off replacement and rebuild gearing for industrial customers.
What is the largest gear you can manufacture?+
We manufacture industrial gears across a very wide size range. Specific limits depend on the gear type and finishing requirements — contact us with your specifications for an exact answer.
How long does it take to manufacture a custom industrial gear?+
Standard turnaround is several weeks; rush turnaround is days. For true emergency replacement gearing, we have manufactured and shipped finished gears in under a week.
Can you manufacture gears from a sample or failed part?+
Yes. Reverse engineering from a sample, failed component, or mating gear is a routine part of our gear manufacturing service.
Do you provide heat treatment and finishing in-house?+
Yes. Hobbing, shaping, grinding, heat treatment, and inspection are all in-house, which is why we can hold rush schedules and quality consistently.