Large metal gears rest on wooden pallets in an industrial workshop, surrounded by other metal components and machinery, with blurred shelves and equipment in the background.

Gear Cutting

At Llewellin’s Gears, we provide precision gear cutting services—including internal helical gears and worm shafts—serving industries that demand tight tolerances, extended service life, and smooth power transmission. Our gear cutting machinery supports low-volume prototypes and small to medium-volume production runs.

Close-up of a metal gear being cut by a milling machine with coolant fluid being applied, showing detailed machining and metalworking process.

Gear Cutting Capabilities

Spur Gears
Helical Gears
Internal Helical Gears
Double Helical Gears
Worm Gears (External Only)
Worm Shafts
Bevel Gears
Internal Gears
Planetary Gears
Sprockets

Materials

Carbon & Alloy Steels
Stainless Steels
Aluminium
Brass & Bronze
Plastics (e.g. POM, Nylon)
Pre-Hardened or Heat-Treated Materials

Capacity

Spur Gear Capacity: Up to Ø2640mm
Internal Spur Gear Capacity: Up to Ø1300mm
Helical Gear Capacity: Up to Ø2135mm
Internal Helical Gear Capacity: Up to Ø1041mm
Double Helical Gear Capacity: Up to Ø1320mm
Worm Wheel Capacity: Up to Ø1830mm
Worm Shaft Capacity: Up to Ø300mm
Bevel Gear Capacity: Up to Ø610mm
Sprocket Capacity: Up to Ø2640mm

Methods

Hobbing – For spur, helical, double helical gears, and worm shafts.

Shaping – Suitable for internal profiles and clearance-critical components.

Planing – Precision method for small batches or custom geometries.

Applications

Gearboxes & Transmissions
Worm Gear Drives
Lifting & Hoisting Systems
Robotics & Automation Equipment
Pumps & Conveyors
Power Tools & Precision Drives

Close-up of metal gears with yellow lubricant oil being poured over them, highlighting the mechanical parts and lubrication process.

Benefits

High Dimensional Accuracy & Repeatability.
Quiet Operation & Smooth Engagement for Helical & Worm Gears.
Internal & External Helical Gear Capabilities.
Long Shaft Cutting for Worm Assemblies.
Fast Turnaround & Flexible Order Quantities.

Close-up view of shiny metal gears and bearings in a mechanical system, highlighting the precise, angled teeth and polished surfaces of the machinery components.

Quality Assurance

All gear cutting is performed under our ISO 9001:2015 certified quality system. Every part undergoes strict dimensional verification using pitch micrometres, gear gauges, and detailed measurement inspection.

Other Capabilities

Broaching

Llewellin’s Machine Company Ltd excels in broaching, a precise machining process used to cut complex profiles, keyways and splines in gears and components. Our state-of-the-art horizontal and vertical broaching machines adhere to ISO 9001 standards, ensuring tight tolerances and exceptional finish quality.

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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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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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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.