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

Our Custom Gear Manufacturing Services

Butler Gear uses state-of-the-art gear manufacturing equipment and processes, to ensure the highest quality and precision of our products.

Although we employ a variety of techniques in the custom gear manufacturing process, these are some of the most common approaches we use to achieve exceptional results for our customers. 

Hobbing

The hobbing process uses a specialized type of milling equipment to cut gear teeth into a desired material. Our team uses hobbing in the fabrication of helical, worm and spur gears, among other products. Using the most advanced technology and hobbing machines, we can quickly and affordably produce a high volume of precision gears. This allows us to provide rapid turnaround and maintain the lowest possible pricing.

Gear Broaching

We use broaching as a way to create highly precise cuts in either a linear or rotary manner. The tool necessary to achieve this result – known as a broach – moves across the surface of the specified material, removing a desired amount of the material and creating the desired shape or pattern. Only a few gear manufacturers offer this highly specialized process and Butler Gear is proud to offer broaching as one of our areas of expertise.

Custom Gear Manufacturing

Gear Grinding

Butler Gear uses the grinding process in a variety of ways, allowing us to fabricate highly precise gears with close tolerances. We employ surface and internal grinding techniques to smooth, polish and deburr, as well as for the purpose of removing irregularities on the gear surfaces after heat treating. The grinding process ensures even wear and quitter operation.

Gear Shaping

Also commonly known as gear turning or cutting, the shaping process begins with raw materials and ends with the basis for what will become a high precision finished product. Butler Gear’s custom gear manufacturing facilities use a variety of high-tech tools and machinery to cut, turn and otherwise shape our products. Our facility uses a variety of cutting equipment, depending on the type of gear we seek to produce.

CNC Milling

CNC milling is a highly versatile and effective process used for a variety of custom gear manufacturing steps, including cutting and drilling. Computer numerical control (CNC) milling uses programmed computer code to remove material, creating a desired shape or pattern. At Butler Gear, we use the most advanced CNC milling equipment and techniques to ensure exceptional quality results.   

The custom gear manufacturing process is constantly changing and evolving as technology advances our capacity for speed and accuracy in the fabrication process. Butler Gear remains on the cutting edge of new manufacturing technology. This allows us to provide our customers with the highest quality, defect-free products with quick turnaround and reasonable pricing. Contact us today to learn more about our custom gear manufacturing processes or to discuss an upcoming order. 

 

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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