We have been used advanced methods for gear design and gear manufacturing for over 20 years. Starting in 1980 we have adopted Direct Digital Simulation method proposed by Dr. Stepan V. Lunin as a primary method for developing gear simulation software.

Spiral Bevel Co, our gear manufacturing partner, provides services in manufacturing of large spiral bevel gears that are commonly used in rock crushers, cone crushers, marine drives, thrusters, z-drives, industrial, and wind power applications. In large spiral bevel gear design it is critical to optimize all the parameters of the gear on computer models before producing the real gear. Large spiral bevel gears are very expensive to manufacture due to limited availability of the gear cutting machines. There are just 6 gear cutting machines in the US that can produce spiral bevel gears larger than 55" in diameter. Three 100-inch Gleason machines and two 80-inch Klingelnberg machines are located in Illinois and belong to two companies. One large 675 Gleason 100-inch machines is in Texas. Each of the six gear machines are capable to produce one gear set every week, which comes to total of 300 gear sets a year. However the gear cutting machines are old and not repeatable. If you come back to these gear manufacturers and ask to reproduce the same gear they will not be able to do so. Even if you bring the machine summary that have been used for gear cutting the resulting tooth surface will be different from what it was befor the machine settings have been changed.

Our software allows to reproduce identical gear to the original. Unlike the traditional gear manufacturing we do not use machine summary in order to keep the records of the spiral bevel tooth geometry. Our software produces exect 3-dimentional geometry of the spiral bevel gear. When we manufacture a new gear we inspectin the new gear against the digital model.