Gear Manufacturing

High-precision gear production from Ø20 mm to Ø1300 mm

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Precision Gear Manufacturing You Can Rely On

Hard Ferr designs and manufactures precision gears trusted in demanding industrial applications. Since 1986, gear production has been a core strength of our business.

We combine advanced CNC and 5-axis machining with dedicated gear cutting to deliver smooth-running, accurate, and durable gears and matching gear racks for new builds, replacements, and engineered upgrades.

Manufacturing is carried out in Hungary under strict quality control, with UK based client support for clear communication from enquiry to delivery.

Our Gear Manufacturing Capabilities

Our expertise covers spur gears, worms and worm wheels, sprockets and splined gears, with diameters from 20 to 1300 millimetres and a module range of 0.5 to 16. We use 5-axis machining centres for complex geometries and precision alignment, then produce tooth forms by hobbing and precision milling.
Where required we apply heat treatment for hardness and wear resistance.
Blanks are prepared on CNC lathes and machining centres. Sinker and wire EDM are used for keyways and special profiles. Every gear is inspected for tooth profile, runout and concentricity, with full dimensional checks against the drawing before release.

What Materials and Sizes We Handle

We manufacture gears from materials specified in the order.
We machine gears from carbon and alloy steels and plastics for strength and wear life, stainless steel for corrosion resistance, and non-ferrous metals such as bronze and brass for quiet running and good bearing properties.
We can also provide complete production with heat treatment carried out by our trusted external partners to meet your load and life targets.

Our working envelope supports diameters up to 1300 millimetres, from small precision gears to large industrial units, and we also manufacture the corresponding gear racks. Batch flexibility covers small batches through to production runs, with prototype samples available within an agreed batch, including replacement gears, matched pairs, and spare parts.

Quality control includes documented process checks and final inspection. Material certificates and inspection reports are available on request.

What Components We Machine

Spur gears and pinions, worms and worm wheels, sprockets, splined hubs and shafts, custom gearing and other mechatronic parts for machinery rebuilds and upgrades.

Our gears are used in automotive workshop equipment such as lifts, wheel balancers, and rotating fixtures for welding systems, as well as in industrial machinery, energy and power generation, oil and gas, marine, and mining applications.

Materials We Use in Gear Manufacturing

  • CARBON STEEL

    Carbon Steel

  • Alloy Steel

    Alloy Steel

  • Stainless Steel

    Stainless Steel

  • Bronze

    Bronze

  • Brass

    Brass

  • Plastic

    Plastic

Examples of our high-quality Gear Manufacturing components

  • Spur gear

    Spur Gear

    Straight-tooth gear for efficient power transfer between parallel shafts.

  • Flat Spur Gear

    Flat Spur Gear

    Compact straight-tooth gear for parallel shaft drives.

  • Spur Pinion Gear

    Spur Pinion Gear

    Compact drive gear for accurate motion and smooth torque transfer.

  • Spur Gear

    Spur Gear

    Compact, high-accuracy gear for smooth, efficient motion transfer.

  • Spur Gear

    Spur Gear

    Delivers efficient, smooth power transfer between parallel shafts.

  • Spur Gear

    Spur Gear

    Straight-cut gear for efficient power transmission.

  • Helical Gear

    Helical Gear

    Angled-tooth gear for smooth, high-load transmission.

  • A shiny metal gear or cogwheel with evenly spaced teeth, viewed from an angle showing its inner hub and teeth.

    Helical Drive Gear

    Precision-machined for high torque and quiet operation.

  • Rack and Pinion Gear Set

    Rack and Pinion Gear Set

    Converts rotary motion into smooth, controlled linear movement.

  • Rack and Pinion Gear

    Rack and Pinion Gear

    High-accuracy setup for smooth linear motion in automation and CNC systems.

  • Splined Shaft with Integrated Gear

    Splined Shaft with Integrated Gear

    Ensures precise torque transfer and alignment in power transmission systems.

  • Splined Gear Shaft

    Splined Gear Shaft

    Integrated splined shaft and gear for high-torque, precision drive systems.

  • Helical Pinion Shaft

    Helical Pinion Shaft

    Precision-cut for smooth, quiet power transmission in gear assemblies.

  • Spur Pinion Shaft

    Spur Pinion Shaft

    Compact gear–shaft unit for precise power transfer in machinery drives.

  • Sprocket Gear

    Sprocket Gear

    Durable sprocket for chain-driven power transmission in machinery and transport systems.

  • Worm and Wheel Gear Set

    Worm and Wheel Gear Set

    Compact gear system providing high torque and smooth motion for precise speed reduction.

  • Gear Racks

    Precision-machined linear gearing for accurate motion control where alignment and tooth quality are critical.

Industries That Rely on Our Gear Manufacturing Expertise

  • Automotive Workshop Equipment

    Automotive Workshop Equipment

    Precision gears manufactured for lifts, wheel balancers, rotating fixtures for welding systems, and other workshop machinery. Built for durability, smooth operation, and long service life in demanding daily use.

  • Industrial Machinery & Equipment Industry

    Industrial Machinery & Equipment

    Core gears for manufacturing equipment, robotics, and automation systems, built for efficiency and long service life.

  • Agricultural Machinery & Farm Equipment

    Agricultural Machinery & Farm Equipment

    Replacement and OEM gears for agricultural machinery and farm equipment, built for strength, reliability, and harsh working environments.

  • Construction Industry

    Construction

    Heavy-duty gears for cranes, excavators, and lifting systems. Built to handle torque, load, and harsh site conditions.

  • Oil and Gas Industry

    Oil & Gas

    Specialised gears for drilling, valve actuation, and pumping systems, designed to withstand pressure, heat, and corrosive environments.

  • Marine Industry

    Marine

    Corrosion-resistant gears for winching systems, handling equipment and other marine mechanisms that require durability and reliable performance in harsh, offshore environments.

  • Mining Industry

    Mining

    Rugged, wear-resistant gears used in conveyors, crushers, and heavy mechanical drives exposed to continuous stress and dust.

  • Energy and power generation industry

    Energy & Power Generation

    High-load gears used in turbines, generators, and control systems, offering performance stability and wear resistance under continuous operation.

  • Defence and Security Industry

    Defence & Security

    High-strength precision gearing for armoured vehicles, radar systems, and mechanical actuation, meeting stringent reliability standards.

  • Medical Industry

    Medical Devices

    High-precision, small-format gears for medical equipment, designed for quiet, vibration-free performance and long-term reliability.

  • Electronics Industry

    Electronics

    Compact gears for assembly equipment and robotics, where fine tolerances and smooth motion are essential.

Our Process

  • 01

    Requirements & Specifications

    We begin every project by reviewing the client’s requirements and specifications.

    These details form the foundation for accurate production, ensuring that dimensions and tolerances are clearly defined from the start.

  • 02

    Material Selection & Preparation

    We source the specified materials, including carbon steel, alloy steels, plastics, stainless steel, bronze, and brass, chosen for their strength, wear resistance, or corrosion resistance.

    The raw stock is then cut into blanks and prepared with initial turning and facing operations to create a precise foundation for gear cutting.

  • 03

    Machining & Gear Production

    Using CNC and hobbing-milling technology, we produce spur gears, worms and worm wheels, sprockets, splined gears, and matching gear racks.
    This ensures consistent accuracy, smooth operation, and repeatability across a wide range of gear types and sizes.

  • 04

    Heat Treatment & Finishing (as required)

    Depending on application, gears may undergo heat treatment to increase hardness and durability, followed by grinding and finishing processes to achieve precision and smooth operation.

  • 05

    Inspection

    All gears are carefully checked against the original specifications using precision measuring tools.

    This ensures compliance with required dimensions, tolerances, and quality standards.

  • 06

    Delivery

    Once approved, the finished gears are cleaned, securely packaged, and delivered across the UK and Europe with full documentation.

A middle-aged man with short dark hair talking on a black corded telephone inside a workshop, wearing a navy blue shirt with 'HARD FERR' embroidered on it.

We’re here to support your next project, from concept to delivery.

Whether you need precision-machined components, tooling solutions, or custom parts, our team is here to help.

We’ll review your requirements carefully and provide accurate pricing with dependable lead times for your project.

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