Aaron Fagan is a Senior Editor for AGMA Media's Gear Technology and Power Transmission Engineering magazines.
As the gear industry steps into 2025, manufacturers are navigating a landscape shaped by geopolitical uncertainties, evolving workforce dynamics, and rapid technological advancements. Alongside Gear Technology’s annual State of the Gear Industry survey, we like to gather insights from leading machine tool manufacturers on the challenges, opportunities, and trends defining the year ahead.
Benoit B. Mandelbrot (1924–2010), the mathematician who coined the term “fractal,” revolutionized the way we understand complexity in nature. His groundbreaking work introduced the concept of self-similar patterns—structures that repeat at varying scales—which appear in phenomena as diverse as coastlines, clouds, and market fluctuations. Fractals provide a mathematical framework for describing irregular shapes and dynamic systems, making them invaluable for tackling problems where traditional linear approaches fall short. Building on Mandelbrot’s groundbreaking work, the application of fractals in engineering reveals exciting possibilities for gear design.
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.
The International Manufacturing Technology Show (IMTS)—September 9–14 at Chicago’s McCormick Place—is the largest manufacturing technology show and marketplace in the Western Hemisphere, and it’s right around the corner! With visitors from more than 110 countries, IMTS is where the creators, builders, sellers and drivers of manufacturing technology come to connect and be inspired. But with more than 1.2 million square feet of exhibit space, where do you begin? Here at Gear Technology, we do our best to help you make the most of your show experience by assembling booth previews that will be worthy of your attention.
The International Manufacturing Technology Show (IMTS) September 9–14 at Chicago’s McCormick Place is fast approaching and, for newcomers and veterans alike, it is always worthwhile to plan as much as possible in advance to make the most of it. For Gear Technology readers looking for gear manufacturing equipment such as gear cutting, forming, and finishing, as well as broaching, shaping, and slotting machines, you must first visit the Gear Generation sector in the North Building, Level 3.
The 10,000-Year Clock, also known as the Clock of the Long Now, is a visionary project aimed at fostering long-term thinking and responsibility. Located inside a mountain in West Texas on land owned by Jeff Bezos, this clock is designed to keep accurate time for 10,000 years, serving as a powerful symbol of longevity and sustainability.
A gear is nothing without its counterparts. Gears work in conjunction with other components within a gear system to achieve specific mechanical functions. These counterparts work together synergistically to form functional gear assemblies capable of transmitting motion and torque, converting speed and torque ratios, and performing a wide range of mechanical tasks in various applications across industries.
Gear Technology regularly covers machine tools, often referred to as “mother machines” due to their role in producing other machines, which serve as the cornerstone of industrial civilization by cutting or shaping metal. Think of all the gears in the machine tools that not only cut and polish gears but are indispensable for manufacturing a wide range of goods, with nearly every product being created either directly using machine tools or through machines manufactured using these tools.
National STEM Day, celebrated on November 8th this year, provided a platform for Gear Technology to engage in a conversation with four remarkable women shaping the manufacturing industry: Ruthie Johnston, CEO and Owner of Croix Gear; Robin Olson, Senior Manager, Applications Engineering—Engineered Gear, Regal Rexnord; Michelle Maddox, Sales and Business Development Manager, B&R Machine and Gear Corp.; and Claudia Hambleton, Office Manager and Corporate Treasurer, German Machine Tools of America (GMTA). Each of these women, driven by a shared passion for fostering the next generation of female leaders, revealed their unique journeys and perspectives in this male-dominated field.
AGMA’s Motion + Power Technology (MPT) Expo is a biennial trade show—running this year from October 17–19 at Huntington Place in Detroit—designed to serve the gear and power transmission industry, representing the full spectrum of professionals involved in the life of a gear, gearbox, or other power transmission device—from design to manufacturing, testing, heat treating, and more. You will find equipment and materials suppliers to make gears; gear and gear drive manufacturers; and every imaginable industry-adjacent supplier from software to tooling, lubrication to bearings, and much more.
The roots of heat-treating run deep within ASM (American Society for Materials) International, as its society was founded in Detroit in 1913 as The Steel Treaters Club. The heat-treating constituency of ASM created the Heat Treating Society (HTS) to provide focused leadership, communications, and service development to its network of worldwide membership of captive and commercial heat treaters, equipment manufacturers, researchers, governments, and technicians. To discuss Heat Treat 2023, the 32nd annual HTS Conference and Exhibition, Gear
Technology took a moment to catch up with conference chair Andrew Banka, vice president of Airflow Sciences Corporation. Heat Treat 2023 is colocated with IMAT and Motion + Power Technology Expo in Detroit, October 17–19.
Three Degrees of Freedom: Notes on an active ball joint mechanism based on spherical gear meshing.
While I was attending the 10th International VDI Conference on Gears 2023—held in Garching, Munich at the Gear Research Center (FZG) of the Technical University of Munich from September 13th to 15th, 2023—Delrin, a product family of DuPont, introduced a new high molecular weight nucleated resin specially formulated for use in applications requiring high creep resistance and fatigue durability.
I had the good fortune to sit down and speak with Guillaume Doy, Global Marketing Leader from Delrin, to hear more about their acetal homopolymer for high-load mechanical applications.
On August 23, 2023, India’s Chandrayaan-3 mission made a successful landing on the southern part of the moon near the crater Manzinus. We were able to catch up with Mushtaq Jamal, vice president of engineering and business development at Bevel Gears India Pvt Ltd (BGI), to discuss BGI's role in this monumental achievement for India.
Heat Treat 2023 is the Heat Treating Society’s 32nd conference and expo for heat treating professionals featuring three days of face-to-face networking opportunities with approximately 200 heat treat exhibitors/companies. All the top heat-treating companies will offer the latest research and industry insights during more than 100 technical programs. This year’s show includes a VIP-guided industry tour, as well as student/emerging professionals initiatives, including free college student registration, Fluxtrol Student Research Competition, and the ASM Heat Treating Society Strong Bar Student Competition. Heat Treat 2023 is colocated with Motion + Power Technology Expo 2023 with access to additional exhibitors. The event takes place October 17–19, 2023 at Huntington Place in Detroit.
The Forging Industry Association’s (FIA) Forge Fair, North America’s largest event dedicated exclusively to the forging industry, returned to the Huntington Convention Center in Cleveland, Ohio, May 23–25, 2023. More than 2,000 forging professionals from across the globe attended Forge Fair to learn about new products, make purchasing decisions, and network with each other. This specialized-industry event offered suppliers and forgers a platform to connect with more qualified potential customers. From material selection to the shipment of finished parts, Forge Fair showcased innovations in heating, tooling, equipment, testing, automation, conservation of resources, process and plant improvements, and technology for all types of forging operations.
Gear Technology readers know diesel—because of the fuel’s properties, such as viscosity, lubricity, and combustion characteristics—can influence the design considerations for gears within the diesel engine. What our readers might not know is on September 30, 1913, The New York Times led with a headline that Rudolf Diesel—multimillionaire inventor of the diesel engine and international superstar in the scientific community—had disappeared from the passenger steamship, Dresden, crossing from Belgium to England and was presumed dead.
Next year, farmers in Colorado will be able to fix their own tractors, and manufacturers will have to provide them with resources to help them do it. In late April, Colorado became the first state to ensure farmers can work on their own equipment with Governor Jared Polis signing “The Consumer Right to Repair Agriculture Equipment Act,” which forces manufacturers to make available the necessary manuals, tools, parts, and software to farmers who rely on complex and expensive machinery, such as tractors, combines, and other farm equipment.
AGMA members descended on Fort Worth, Texas, from all corners of the country (and industry!) for three days of the 2023 Strategic Networking and Leadership Forum sponsored by Gleason Corporation, WD Bearings, Blaser Swisslube, and Specialty Steel Treating. Professionals from gear shops and OEMs alike gathered to share their experience and insight about where we are as an industry and where we're going.
In this interview, we learn about Gleason Plastic Gears (GPG), a division of Gleason Corporation that specializes in designing and manufacturing plastic gears using their proprietary no-weldline technology. GPG has diversified its customer base and serves various industries such as automotive, medical, electronics, home and leisure, marine, education, and hobby. The interview covers topics such as the advantages of the no-weldline technology, surprising applications where plastic gears are replacing metal gears, promising materials and methods for the future of plastic gears, challenges faced by plastic gear designers, and recent developments in services, software, and manufacturing technology.
Player Piano serves as a cautionary tale and remains relevant in the age of automation as it addresses the issues of technological progress and the impact of replacing human labor and the resulting loss of purpose and meaning in life. It highlights the consequences of relying too heavily on machines and the need to find a balance between progress and preserving the human spirit. The novel remains relevant as discussions around the future of work, job loss due to automation, and the ethics of artificial intelligence continue to be important topics in today’s society.
The American Gear Manufacturers Association (AGMA) recently applied for and received reaccreditation from the International Accreditors for Continuing Education and Training (IACET) organization for its educational courses. An IACET accreditation allows gear industry professionals to earn Continuing Education Units (CEUs) for attending AGMA courses. To celebrate, Gear Technology caught up with Stephanie Smialek, Education Manager, AGMA, to discuss the full breadth of AGMA’s professional development programs.
Furnaces North America 2022 (FNA 2022), presented by the Metal Treating Institute (MTI), in partnership with its media partner, Heat Treat Today, is the heat-treating industry’s go-to event every other year. FNA 2022 attracted attendees from across North America, including Fortune 500 companies. For three days attendees took part in networking, connections, and learning about the vast changes taking place in emerging technologies, industry trends, and advances in equipment.
With our zeitgeist of presentism—the judging of the past through the lens of current standards—it’s refreshing if not essential to know the past was not entirely without figures who not only exceeded the standards of their time but even those of today. At a time when women’s suffrage was in its nascency, Catherine “Kate” Anselm Gleason (1865–1933) helped stage what would become the Gleason Corporation in the global cutting tools industry as a sales engineer for her family’s gear-cutting machinery business.
Workholding solutions increase throughput which generates uptime because they greatly reduce setup and changeover times. Operators can change workpieces in a highly repeatable manner which significantly increases the quality of the finished part. The primary function of streamlining production is to develop a workholding solution that optimizes the machining of multiple parts at once while maintaining tight tolerances. Below you will find a cross-section of companies that will be showcasing their approach to workholding systems at IMTS from Sept. 12–17 at McCormick Place in Chicago.
Furnaces North America 2022 (FNA 2022), presented by the Metal Treating Institute (MTI), in partnership with its media partner, Heat Treat Today, is the heat-treating industry’s marquee event every other year. FNA 2022 will attract attendees from across North America, including Fortune 500 companies. For three days attendees take part in networking, connections, and learning about the vast changes taking place on emerging technologies, industry trends, and advances in equipment.
The mere mention of artificial intelligence (AI) often conjures one dystopian vision or another—perhaps the prime example of all is the HAL 9000 going spectacularly awry in the film 2001: A Space Odyssey. The prospect of the widespread adoption of AI is understandably alarming to people in a host of ways, but be that as it may, various forms of it are already a central part of how things are done—from finance to health care, from heavy machinery to retail—and the reason for this is simple: AI allows computers to do things people can’t unassisted, and by pairing algorithmic accuracy with automation, this helps save valuable time and resources. However, as AI and other control mechanisms affecting systems grow increasingly sophisticated, the human link to these processes becomes critical.
Additive Manufacturing (AM) is a space that is maturing at insensate speed—the growth and innovation in materials and technology are staggering. Because of the inherent process of 3D printing, it may allow for a renaissance in the physical design of gears (i.e., integral channels for cooling, lightweighting, and other possibilities) but also holds the potential for gear repairs. Gear Technology spoke with JEOL, Nidec, and Fortify about the technologies they will be on-site to discuss at IMTS 2022.
AddUp, a joint venture created by Michelin and Fives, is a global metal additive manufacturing OEM and service provider of powder bed fusion (PBF) and directed energy deposition (DED) technologies. They have launched a suite of new process monitoring software to bolster the capabilities of the FormUp 350 PBF machine: AddUp Dashboards, Recoat Monitoring, and Meltpool Monitoring. This new software suite for its metal 3D printing technology optimizes part quality for prototyping and end-use industrial applications.
Nidec Machine Tool Corporation recently developed the "SE25FR Plus," a gear shaping machine dedicated to making high-precision small-module gears used in robots. The company simultaneously developed a small-module cutting tool specifically for the new gear shaping machine. By providing this dual support in high-precision gear cutting machines and cutting tools from a single source, Nidec Machine Tool responds to the need for reduction gears of increasingly higher precision in the expanding global robot market.
The way to increase production, especially with the largest gears, is to decrease nonproductive time with improved strategies.
Noncircular gears are not a mere mathematical curiosity with limited practical utility. They were first sketched by Leonardo da Vinci around 1500 and have since found their way into a variety of useful applications. In the 18th century, noncircular gears were used in flow pumps, clocks, music boxes, toys, and other devices. Early publications on the gear type in the 19th century by Hamnet Holditch (1842), Henry T. Brown (1871), and Franz Reuleaux (1875) helped evolve the field of kinematics. First introduced by Uno Ollson in his book Non-Circular Bevel Gear in 1959, the noncircular bevel gear has remained obscure due to the complex geometry. Even though more and more publications are available on noncircular gears, the knowledge is, especially compared to cylindrical gears, still very limited. But in the last decade, there has been an increased interest in the field of noncircular gears due to certain advantages they have over circular gears.
In July, Raymond J. Drago, P.E.—chief engineer of Drive Systems Technology, Inc. (DST), a mechanical power transmission consulting organization that he founded in 1976—will lead an IACET-accredited course on both the geometry and rating of involute splines of various types along with their applications. Topics under discussion include spline configuration variations, including half depth, full depth, and special function designs; both fixed and flexible spline configurations in terms of usage and design; lubrication methods, including grease, oil bath, and flowing oil, as well as coatings appropriate for various spline applications; and shear and compressive stress rating methods with analyses methodology in both equation and graphical methodology via various rating charts.
When it comes to noise, vibration and harshness (NVH), I’m reminded of that dog-van scene from Dumb and Dumber where Jim Carrey says, “Want to hear the most annoying sound in the world?” and then proceeds to emit an astonishingly awful noise. Annoying as NVH may be, it’s a key metric in drive-system development for e-mobility, and the careful design and manufacture of gears are crucial to minimizing NVH as tolerance variations can result in large differences between nominally identical components.
Cutting tools are basic to gear manufacturing. Whether it's a hob, broach, shaper cutter, or skiving tools, the mission of cutting tools remains the same as always: bulk material removal that is fast, precise, and cost-effective. Evolution in the field tends to come gradually over time in the machines, materials, and coatings that make cutting tools even more useful. Reliable cutting tools are essential to production-process efficiency, and recent solutions from Kennametal, Star SU, and Seco offer improved tool life and precision.
The 34th annual Control 2022 international trade fair in Stuttgart, Germany, is the place to be when it comes to measuring and test technology, materials testing, analysis equipment, vision technology, image processing, and sensor technology, as well as weighing and counting technology. The exhibitor forum will provide expert visitors with the opportunity of finding out more about the product and service portfolios and the technological expertise offered by individual companies such as Gleason and Klingelnberg, which will both debut new solutions from their portfolios.
KISSsoft is a well-known software system that addresses gear manufacturing as a holistic process. With over 4,000 licenses sold worldwide, its functionality is dedicated to gear manufacturing and gear inspection and makes it easier for engineers—in the areas of calculation, manufacturing, and quality assurance—to collaborate and exchange data.
New drive technologies in e-mobility are changing the requirements for gears and, therefore, the quality of the tooth-flank surfaces. Manufacturers of gears have to adapt their manufacturing process accordingly. It’s good to be able to rely on a technology partner with expertise covering the entire range of production processes and technologies, which enables them to find suitable solutions even for special challenges.
Solvay, observing key trends and factors affecting the transportation sector, has developed, tested, and applied materials for a wide variety of automotive uses. Central to those objectives are efficiency and regulatory targets, engine size reduction, increased electrification of the powertrain, low NVH, and higher efficiency through lightweighting. It’s no longer a question of whether high-performance plastics are meeting NVH and other challenges in e-mobility environments, but which polymers are good for high-performance gears?
Production demands continue to rise with the burgeoning electrification movement. The desire for high-precision gears and low-cost manufacturing requires versatile and affordable high-efficiency processing to serve the needs of a variety of industries. Gathered here are a few recent hobbing solutions from Affolter Group, Helios Gear Products, and Nidec Machine Tool Corporation.
Virtual prototyping (VP) is an area where huge advances have been made. As gear and transmission systems, and the methods of their production, become more complex and more interdependent, finding ways to use VP across the entire development process—from the initial design, through analysis, right up to manufacturing—ultimately means gaining a better understanding of system performance and efficiency.
Applying their Materials by Design methodologies, QuesTek Innovations has expanded their ICME framework under US Army Small Business Innovation Research (SBIR) funding to adapt their high-performance Ferrium C64 gear steel to AM processes to demonstrate printability across multiple systems, achieve AMS minimum tensile properties, and observe a positive response to heat treatment.
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