Custom Plastic Gears – Precision Injection Molded Polymer Gear Solutions
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Service Item
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Details
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Technical Parameters
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Delivery Time
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Gear Design
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Custom gear geometry optimization
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Module 0.1-5.0, Pressure angle 20°
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Design: 3-5 daysPrototype: 7-10 days
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Injection Molding
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High-volume production
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POM/PA/PEEK materialsISO 5-7 precision grade
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Sample: 5-8 daysBulk: 15-20 days
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CNC Machining
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Low-volume precision gears
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±0.005mm toleranceComplex geometries
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Sample: 3-5 daysBulk: 10-15 days
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Material Selection
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Engineering polymers
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POM, PA66+GF, PEEKSelf-lubricating grades
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Based on material inventory
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Quality Testing
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Comprehensive inspection
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CMM measurementNVH performance testing
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Production synchronous
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Surface Treatment
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Special coatings
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Lubrication enhancementWear resistance coating
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2-3 days finishing
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Description
Precision Engineered Custom Plastic Gears
Innovative Polymer Solutions for Modern Transmission Systems
Discover our advanced custom plastic gear solutions, where cutting-edge polymer technology meets precision engineering. Our gears offer exceptional performance benefits including lightweight design, quiet operation, and superior durability compared to traditional metal gears.
Advanced Polymer Technology
High-Performance Materials
- POM (Polyoxymethylene): Excellent self-lubrication, high rigidity, dimensional stability
- Nylon (PA66+GF): Reinforced with glass fiber for increased strength and wear resistance
- PEEK: Ultra-high performance polymer for extreme temperature and chemical resistance
- Custom Blends: Tailored material formulations for specific application requirements
Material Advantages
- Lightweight: 70-80% weight reduction compared to metal gears
- Self-Lubricating: Eliminates need for additional lubrication systems
- Corrosion Resistant: Superior performance in harsh chemical environments
- Noise Reduction: NVH performance improved by 50% (3dB reduction)
Precision Manufacturing Processes
Injection Molding Excellence
- High-Volume Production: Economical solution for mass production requirements
- Tight Tolerances: Achievable precision up to ISO 5 grade standards
- Complex Geometries: Ability to produce intricate gear designs in one step
- Consistency: Uniform quality across thousands of identical components
CNC Machining Precision
- Low-Volume Production: Ideal for prototypes and small batch requirements
- Micro-Precision: Tolerances as tight as ±0.005mm for critical applications
- Material Versatility: Capable of machining all engineering polymers
- Rapid Turnaround: Fast production for time-sensitive projects
Gear Design Capabilities
Comprehensive Gear Types
- Spur Gears: Straight-cut gears for parallel shaft applications
- Helical Gears: Angled teeth for smoother, quieter operation
- Bevel Gears: Conical gears for 90° power transmission
- Worm Gears: High reduction ratio in compact design
- Internal Gears: Gears with teeth on the inner diameter
- Gear Racks: Linear motion conversion components
Design Optimization
- Tooth Profile Modification: Custom tooth geometry for optimal performance
- Noise Reduction Design: Special tooth profiles to minimize operating noise
- Load Distribution Analysis: Finite element analysis for maximum durability
- Material Selection Guidance: Expert recommendations for your specific application
Technical Specifications
Precision Parameters
- Module Range: 0.1mm to 5.0mm
- Pressure Angle: Standard 20°, custom angles available
- Precision Grade: ISO 5 to ISO 7
- Dimensional Tolerance: ±0.002mm to ±0.01mm
- Surface Finish: Ra 0.2μm and below
- Maximum Diameter: Up to 300mm
Performance Characteristics
- Operating Temperature: -40°C to +260°C (depending on material)
- Load Capacity: Up to 500N/mm tooth width
- Rotational Speed: Up to 10,000 RPM
- Service Life: Millions of cycles with proper maintenance
Application Solutions
Automotive Industry
- Electric power steering systems
- Transmission components
- Fuel system pumps
- HVAC systems
- Window regulators
Medical Devices
- Surgical instruments
- Diagnostic equipment
- Patient care devices
- Laboratory automation
- Dental equipment
Robotics & Automation
- Collaborative robots
- Industrial automation
- AGV navigation systems
- Pick-and-place machines
- Precision positioning systems
Consumer Electronics
- Printers and copiers
- Home appliances
- Office equipment
- Camera systems
- Audio equipment
Quality Assurance
Stringent Testing Procedures
- Dimensional Inspection: CMM measurement for precision verification
- Material Analysis: Spectroscopy for material composition confirmation
- Performance Testing: NVH measurement, wear testing, fatigue testing
- Environmental Testing: Temperature, humidity, and chemical exposure testing
Certifications & Standards
- ISO 9001:2015 Quality Management System
- IATF 16949 Automotive Quality Standard
- RoHS and REACH Compliance
- FDA Compliance for medical applications
Why Choose Our Custom Plastic Gears
Technical Expertise
- Decades of experience in polymer gear engineering
- In-house design and manufacturing capabilities
- Continuous research and development
Cost-Effective Solutions
- Reduced production costs compared to metal gears
- Elimination of secondary operations
- Lower maintenance requirements
Environmental Benefits
- Reduced energy consumption
- Recyclable materials
- Lower carbon footprint
Global Support
- Worldwide shipping capabilities
- Local technical support
- Customized logistics solutions
Partner with us for innovative plastic gear solutions that drive your business forward with superior performance, reliability, and cost efficiency.
