Close-up of a metal rod being machined on a lathe, with metal shavings scattered around and industrial machinery in the background.

Broaching

At Llewellin’s Gears, we offer precision internal broaching services ideal for producing high-accuracy forms such as keyways, splines, and custom profiles. Our broaching operations are engineered for consistency, speed, and tight tolerance control — helping you achieve production efficiency without compromising on quality.

Close-up of multiple metal gears arranged in rows, with a shallow depth of field focusing on the central gears and blurring those in the background.

Broaching Capabilities

Keyways
Splines
Hexagonal & Square Holes
Round-to-Shape Transitions

Materials

Mild & Stainless Steels
Aluminium, Brass & Bronze
Titanium & Specialty Alloys

Broach Tooling

In-House Tool Setup & Calibration.
Custom Broach Tool Design to Customer’s Drawing.
Large Stock of In-House Broaches.

Close-up of three parallel metal machine parts with intricate grooves and ridges, set against a black background. The surfaces are shiny and reflect light, highlighting their detailed, industrial design.

Why Choose Broaching?

Speed & Efficiency: High-speed material removal ideal for production volumes.
Accuracy: Achieve consistent tight tolerances.
Repeatability: Perfect for components requiring uniform features across batches.
Surface Finish: Excellent surface finishes reduce the need for secondary operations.

Close-up of a heavy-duty industrial gearbox with two large steel shafts extending outward, mounted on a yellow metal base in a workshop setting. The gearbox has a rust-orange and metallic finish.

Quality Assurance

All components undergo rigorous inspection using precision gauges and documented processes. Our broaching services operate within a robust ISO 9001:2015-compliant quality management system.

Other Capabilities

Gear Cutting

Established in 1883, Llewellin’s has been at the forefront of Britain’s gear manufacturing industry for over a century.

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Gear Grinding

Llewellin’s specialises in precision gear grinding, a vital process in the manufacture and finishing of gears for optimal performance.

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Gearbox Refurbishment

At Llewellin’s, we pride ourselves on being a leader in the design, manufacture, and refurbishment of precision gears, gearboxes, and transmission systems.

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Grinding

Llewellin’s Machine Company Ltd offers advanced grinding capabilities using state-of-the-art equipment and techniques. Our precision engineers guarantee all work adheres to stringent industry standards such as ISO 9001 and AS9100, delivering exceptional accuracy and surface finishes for diverse applications. Encompassing surface grinding, cylindrical grinding and centreless grinding, said capabilities are carefully optimised to achieve micron-level tolerances (±0.001 mm) and impeccable finishes. We also offer gear grinding, which you can learn about on its own dedicated page.

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Crane Winch Refurbishment

At Llewellin’s, we combine over a century of expertise in the design, manufacture, and maintenance of offshore winches and gearboxes.

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Reverse Engineering

Llewellin’s reverse engineering capability empowers clients to replicate and enhance legacy components, particularly when original designs or tooling are unavailable. Using advanced metrology equipment, including coordinate measuring machines (CMMs) compliant with ISO 10360-2 standards, we create precise 3D models of existing components.

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Slotting

Llewellin’s slotting capabilities enable precision machining for internal keyways, grooves and slots in gears, pulleys and other critical components. Using high-precision vertical slotting machines, we meet tight tolerances in compliance with BS ISO 286 standards.

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Spline Cutting

Llewellin’s are proud to have become recognised as leaders in precision spline cutting and gear manufacturing since first forming back in 1883.

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Tooth Rounding

Llewellin’s tooth rounding capabilities ensure gears meet stringent performance and durability standards, the kinds required in industries such as aerospace, rail and renewable energy.

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Turning & Milling

Our turning and milling capabilities allow us to produce high-precision components for UK clients positioned across a diverse range of sectors, including defence, aerospace and mining.

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Wire Erosion

Llewellin’s Machine Company Ltd is highly proficient in the science of wire erosion, a capability offering unparalleled precision in machining intricate geometries and fine tolerances.

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A vintage yellow and black open-top car with tufted black leather seats, brass headlamps, and large spoked wheels, displayed indoors among other classic vehicles.

Provide a first class service from a long standing professional company run by experienced and proper people. Many thanks for the parts remade for my vintage Peugeot Bebe.