Custom Gear Blanks

Gears are toothed, mechanical transmission elements used to transfer motion and power between components. The automobiles, aircraft, and heavy-duty industrial machines that make life convenient aren’t possible without gears.

Improve your gear manufacturing capabilities with gear blanks from U.S. Bronze Foundry & Machine. Our gear worm blanks are cast and machined to tight tolerances, and they arrive at your facility ready to be cut, shaped, or hobbed. 

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Custom Gear Blanks

Benefits of gear blanks

A gear blank is a semi-finished component that’s undergone all necessary processing, such as heat treatment and machining, except for the cutting of gear teeth. Gear blanks enable shops to produce finished gears faster because bottlenecks associated with time-consuming prep work are removed.

Gear manufacturers cut, hob, or shape the blanks to appropriate dimensions without performing earlier processes. Integrating gear blanks into your geared product manufacturing process reduces the need for specialized machines or tying up equipment that’s better served performing other operations.

Your gear worm blank source

U.S. Bronze Foundry & Machine is a one-stop provider of standard and custom gear blanks for clients who manufacture gears for heavy equipment and machinery. From product realization to shipment, we handle every metal casting step in-house. Here are our capabilities: 

  • Research & Design
  • Mold-Making
  • Prototyping
  • Full-Scale Casting 
  • Finished Machining
  • Inspection 
  • Delivery 

We produce gear worm blanks with centrifugal and static casting techniques. Built-in automation and controls ensure heightened precision and quality. The ability to manufacture large cast items sets us apart. 

  • Castings up to 35,000 pounds
  • Lengths of up to 80 inches for centrifugally cast parts
  • Outside diameters as large as 158 inches for centrifugally cast parts
  • No size limit for statically cast parts

An onsite machine shop enables us to deliver finished castings with precise dimensions. As a result, the lead time associated with secondary processing is eliminated. The shop contains advanced CNC equipment capable of machining workpieces with: 

  • Outside diameters of 150 inches
  • Lengths of 80 inches 
  • Tolerances are +/- .001 inches

Quality products, without the wait 

Clients expect that once products arrive at their shop, they should be ready to be cut or hobbed for use in complex geared mechanisms. As a leading gear blanks manufacturer, our attention to detail ensures client gear manufacturing runs like clockwork.

Materials that stand up to wear 

When developing new products, it’s essential to consider the mechanical attributes of materials. They can impact final assembly performance. 

U.S. Bronze Foundry & Machine has the experience and metallurgical knowledge to help you identify the best metal alloys for your application. Those we use regularly include: 

We can work with other materials upon request. 

Specialty gear blanks for demanding applications 

At U.S. Bronze Foundry & Machine, we take the hassle out of gear production. Our gear blanks are manufactured to client specifications and arrive ready for insertion onto your CNC machines directly from the receiving dock. 

Gear blanks we manufacture are used to make gears for a variety of applications. Here are some examples: 

Gear Blanks Manufacturer

Our quality management system 

We have a stringent quality management system that ensures every casted component meets applicable industry standards or client specifications. Our shop can produce rough parts as quickly as two weeks and finished pieces as fast as eight weeks, depending on lead time and other factors. 

Please contact our Pennsylvania office to learn more about our gear blank manufacturing process. Our experts are happy to discuss your needs further. 

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