Industrial Forged Spur Gears

We can manufacture shaped spur gears up to 20 inches (500mm) in diameter with a maximum face width of 5 inches (127mm), and hobbed spur gears up to 16 inches (400mm) in diameter. Profile tooth grinding is available for external spur gears up to 15.75 inches (400mm) in diameter.

Our spur gears are produced using hobbing, shaping, and precision profile tooth grinding. These processes are selected based on gear geometry, tolerance requirements, and production volume. We also offer broaching for internal features, and all processes are completed in-house at our 18,000 sq ft Locust, NC facility.

Yes. Carnes-Miller Gear offers full turn-key custom spur gear manufacturing, including gear blanking, machining, and finished gear production complete to customer drawings. We also provide reverse engineering services for obsolete or legacy gears where drawings are unavailable, leveraging over 50 years of gear design and manufacturing expertise.

Our forged spur gears serve a broad range of industries including industrial machinery, mining, transportation, construction, agricultural equipment, rail, aerospace, defense, and medical sectors. We also support OEM manufacturers needing custom gears and aftermarket customers requiring replacement parts for legacy or obsolete equipment.

Yes. Carnes-Miller Gear provides reverse engineering services for obsolete or worn spur gears where original drawings or manufacturer data are unavailable. Our engineering team performs dimensional analysis and replicates the gear to match original specifications or improve upon them, ensuring a reliable replacement for critical drive systems.

Our quality process includes in-house nital-etch testing to detect grinding burns, process planning with dimensional data collection tied to each part, and Gear Chart validation for lead, profile, and tip relief modifications. Specialized certifications are collected and tied to manufactured parts, ensuring traceability and compliance with customer and industry standards.