Butler Gear Enterprises, LLC. | Complete Job Shop Gear Manufacturer

Custom Gear Manufacturing Services

Custom Gear Manufacturing At Butler Gear, our roots in gear manufacturing date back to 1960. We supply customers with high-quality custom gears manufactured from almost any material and in virtually any size and configuration. With our exemplary service and extremely competitive pricing, our customers range from Fortune 500 companies to small job shops in the drilling, oil, automotive, food service, military, agricultural, government, aerospace, and other demanding industries. We have a strong engineering background, and our staff is always ready to assist with engineering, material specification, and problem-solving.

Our portfolio of custom gear and transmission products includes spur, helical, and worm gear sets with capacities up to 80" in diameter. We also produce bevel, rack & pinion, and planetary gears and specialize in internal shaping. Along with flat and hex shafts, gear features include British Standard Metric, cycloidal, involute, straight, and Fellows 20° stub gear tooth forms.

We operate a state-of-the-art manufacturing plant and use a variety of manufacturing processes to cut and form gears. Our forming capabilities include casting, forging, and molding as well as stamping, punching and powder metal processing. Along with conventional hobbing and gear milling, we use EDM, flame cutting, and various other methods of gear cutting. We produce gears from an extensive selection of metals, plastics, and non-metals, and we offer many options for finishing and heat-treating. All gear manufacturing is accomplished through a combination of our in-house capabilities and a network of trusted outsourcing partners.

As an ISO 9001:2015 certified gear manufacturer, we place a strong emphasis on quality and adhere to the key principles of Lean and Six Sigma in all of our production systems. Our gears exhibit a premium level of craftsmanship and conform to the most rigorous and challenging design and quality criteria. To request a quote for a custom gear or to learn more about our gear manufacturing capabilities, contact us directly.

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Portfolios


Custom Gear Manufacturing Capabilities

Gear Types
Bevel
Change
Crown
Rack
Worm
Helical
Herringbone
Hypoid
Internal
Planetary
Pinion
Rack
Spur
Timing
Worm
Gear Tooth Forms British Standard Metric
Cycloidal
Fellows 20° Stub Tooth System
Involute
Straight
Shaft Feature Flat
Hex
Gear Cutting Method Broaching
Climb Hobbing
Conventional Hobbing
EDM
Flame Cutting
Milling
Shaping
Shear-Speed Cutting
Gear Forming Method Centrifugal Casting
Die Casting
Forging
Injection Molding
Plaster Casting
Powder Metal/Sintering
Punching
Roll Forming
Sand Casting
Stamping
Typical Materials
Acetal/Delrin
Alloy Steel
Aluminum
Brass
Bronze
Carbon Steel
Ductile Iron
Gray Cast Iron
Nylon
Plastic
Phenolic
Polycarbonate
Polyester
Stainless Steel
Virtually Any Metal or Non-Metal
Gear Finishing Methods Burnishing
Grinding
Honing
Lapping
Plating
Shaving
Heat Treatment Methods Carburizing
Flame
Induction
Nitriding
Helix Angle
Min
Max
45°
Gear Ratio Open
Number of Teeth Per dimension
Diametral Pitch
Min
96
Max
1 DP
Pitch Diameter Up to 88”
Length Up to 168”
Part Weight Up to 15,000 lbs.
Tolerance (+/-) ±.001”
Production Volume Prototype
Low Volume
High Volume
Blanket Orders
Lead Times Hours to Weeks
  • Quoted on job by job basis
  • Emergency services available
  • Rush services available
Efficiency
Six Sigma Certification
  • Yellow Belt
  • Green Belt
  • Black Belt
Lights Out Manufacturing
Lean Manufacturing
Kaizen/5S
Certifications ISO 9001:2015 Certified

Additional Information

Industry Focus
Aerospace
Agricultural & Farming
Alternative Energy
Auto/Truck/Transportation
Automation
Defense Industry
Energy
Food Production
Food Handling
Food Processing
Food & Beverage
Fracking
Heavy Equipment
Hydraulics
Industrial
Machine Tools
Machinery
Manufacturing
Marine
Material Handling & Processing
Mining
Oil & Gas Pipeline
Oil Field
Oil, Gas, Petroleum Exploration
Oil, Gas, Petroleum Extraction
Packaging
Packaging & Converting
Paper & Pulp Paper Mill
Power Generation
Power Generation Nuclear
Power Generation Alternative
Power Generation Solar
Power Generation Wind
Power Generation Coal
Printing
Pulp & Paper
Pulp Manufacturing
Pumps
Railroad
Recreational
Robotics
Tool & Die
Transportation
Turf & Garden
Universities & Learning Institutions
Waste Management
Wastewater
Water & Wastewater Treatment
Industry Standards ISO
International Organization for Standardization
File Formats
AlphaCAM (AMD, ATD)
AutoCAD (DWG, DWZ)
BMP
Bit Mapped Graphics
Catia (CATDrawing, CATPart)
Delcam (DGK, DMT)
DXF
Drawing Interchange Format, or Drawing Exchange Format
GIF
Graphics Interchange Format
IGES
Initial Graphics Exchange Specification
ANSI file format
Inventor (IDW, IPT)
IronCAD (ICD, ICS)
JPG or JPEG
Joint Photographic Experts Group
MasterCam (MDX, MC8, MC9, SET)
PDES
Product Data Exchange
using STEP, Standard for the
Exchange of Product Model Data.
A standard format for
exchanging data
between advanced
CAD and CAM programs
PDF
Portable Document Format
Pro-E or Pro/Engineer (DRW, PRT, XPR)
SAT
3D ACIS Model File
SolidEdge (DFT)
SolidWorks (SLDPRT, SLDDRW, SLDDRT)
STEP
Standard for the Exchange of Product Model Data
SurfCam (DSN)
TIFF
Tagged Image File Format
TurboCAD (TCW, TCX)
Unigraphics (PRT)

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