Reverse Engineering

Llewellin’s Gears recreates precision components with confidence. We offer expert reverse engineering services to reproduce high-performance components when original drawings, CAD models, or specifications are unavailable. Whether you’re restoring legacy equipment, replacing worn gears, or improving performance, our process ensures accuracy, repeatability, and a perfect functional match.

A close-up of a gear-cutting tool being measured with a precision probe. The gold-colored cutting edges are arranged in a helical pattern, and the background is blurred with green and blue tones.

Reverse Engineering Capabilities

Spur & Helical Gears
Worm Gears & Shafts
Bevel Gears
Spline Shafts
Internal Gears
Custom Machined Parts
Gearbox Components

Applications

Equipment Restoration & Obsolescence Replacement.
Legacy System Support.
Spare Part Reproduction.
Performance Enhancement & Redesign.
Failure Investigation & Root Cause Analysis.

Why Choose Llewellin’s Gears for Reverse Engineering?

Decades of experience in gears and precision parts.
Full Dimensional Replication of Worn or Undocumented Components.
CAD modelling and drawing generation included.
One-off or Production-Ready Output.
ISO 9001:2015 Certified Processes.

A person’s hand uses a bore gauge to measure the internal diameter of a large metal gear in an industrial workshop setting.

What is Reverse Engineering?

Reverse engineering is the process of deconstructing a physical component to extract its design, dimensions, materials, and manufacturing intent. By using precision measurement tools and engineering expertise, we can create a complete digital replica ready for reproduction, improvement, or documentation.

Close-up view of several interlocking, rusted blue metal gears and cogs in a mechanical device, highlighting the intricate details and worn texture of the machinery.

Quality Assurance

All reverse engineering projects follow our ISO 9001:2015 quality management system. From initial inspection to final verification, components are measured and validated using calibrated tools to ensure a faithful and functional reproduction.

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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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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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.