Since I have had the privilege of visiting numerous gear plants and research centers in the U.S., as well as 170 in 33 countries, and I closely watch the progression of technology, I wanted to share my observations about some technological advancements. For the purpose of this article, I will focus on three key areas: Robotics, Machine Tools, and Heat Treating.

As you navigate the ever-evolving landscape of gear manufacturing, it’s become increasingly clear that success isn’t solely determined by the precision of your machines or the latest technological advancements. While these factors remain crucial, the true differentiator in today’s competitive market lies in cultivating and nurturing your most valuable asset: your people.

Zahnradfertigung OTT GmbH & Co. KG was the first company to install the new fully automatic CNC-controlled P 152 precision measuring center from Klingelnberg in its ultra-modern machine park.

Gears that aren’t properly chamfered and deburred can lead to overloaded edges and unanticipated and undesirable noise. This is particularly true in EV applications where torque transmission, unlike combustion engine vehicles, goes from zero to a much higher maximum almost instantly. As a result, EV gears require hard finishing (honing and threaded wheel grinding), and chamfering/deburring becomes critical. 

It was a busy year for the gear industry. Large and small companies had to navigate the interest rates, tariffs, supply chain disruptions, labor shortages, and the unknown economic outlook with an election year in the U.S. Leaders that normally would be brainstorming their five-year strategic plans had to get comfortable with a day-to-day strategy. As each quarter ended, however, AGMA witnessed resiliency, innovation, collaboration, and even quite a bit of growth for some sectors—it was an exciting year to visit members in person.

By 2030, the global robotics market size is expected to range anywhere from $160 billion to $260 billion. The world is expecting robots to do a lot of the “heavy lifting” going forward. But with demand pressuring supply for many of the essential components, new production technologies are needed to keep pace. Nowhere is this truer than for the smaller, high-precision spiral and hypoid bevel gears that play such a critical role in transmitting power and delivering precise, reliable movement in increasingly complex, multiaxis robotic systems. Yet, manufacturers of these gears have, up until now, had surprisingly few options available to help them ramp up production of this new generation of high-efficiency bevel gears—particularly in the increasingly common size range of 100 mm in diameter and smaller. 

This article by Reishauer AG summarizes the insights gained from digitization in the machine tool sector, highlighting the long-term collaboration between the two companies. ZF Getriebe Brandenburg GmbH, distinguished by a team of over 1,500 specialists, leads in producing exclusive manual and dual-clutch passenger car transmissions used in high-end German sports cars for maximum precision and performance. A crucial factor in the quality of these transmissions is the precise ground gears manufactured on machines from Reishauer AG, a Swiss pioneer in gear grinding machines. 

For more than 60 years, Forest City Gear has crafted a legacy of excellence in precision gear manufacturing, leveraging advanced techniques and cutting-edge technology to earn the business of customers as exclusive as NASA. At the heart of the company’s technology-focused philosophy lies a long-time relationship with Sunnen Products Company, a leading manufacturer of honing systems, tooling, and accessories. The relationship helped Forest City set itself apart as one of the world’s most precise gear makers, and now the company’s parts are found on everything from fishing reels to the Mars Rovers.

The importance of clean air in manufacturing is often underestimated, yet it’s one of the critical elements that can impact both production efficiency and employee well-being. This is particularly true in facilities that rely heavily on CNC machining, where oil mist and coolant byproducts can create significant air quality challenges. Wolfram Manufacturing, based in Austin, has addressed this challenge head-on by integrating advanced mist collection systems into its operations.

As the automotive industry continues to move towards e-mobility, the manufacturing world is adapting to the respective requirements. Large gear ratios are necessary to reduce the high input speeds of electric motors to the required speed of the drive wheels. At the same time, masking noise of combustion engines is now missing, posing challenges to the noise level of transmissions. Principally, two main transmission concepts have become established for e-drive applications: two-stage layshaft transmissions with four gears, and planetary transmissions.