Two large, shiny metal machine shafts with grooves are placed on a wooden surface, alongside other industrial metal components.

Spline Cutting

At Llewellin’s Gears, we specialise in high-precision spline cutting services for both internal and external profiles. Whether you need standard or custom spline forms, we deliver consistent accuracy, superior fit, and repeatable performance — even for the most demanding applications.

A large, shiny metal gear shaft with precision-cut teeth lies on a rough, speckled surface, likely in an industrial or workshop setting.

Spline Cutting Capabilities

External & Internal Splines
Straight Sided & Involute Splines
Parallel Key Splines
Helical Splines (External & Internal)
Custom Profiles to Drawing/Spec

Materials

Alloy & Carbon Steels
Stainless Steel
Aluminium & Brass
Tool Steels
Hardened & Heat-Treated Parts

Capacity

Spline Modules: 0.25 to 13 Mod
Lengths: Up to 3150mm
Internal Spline Bores: Up to 1300mm
External Spline: Up to Ø2640mm

Methods

Slotting
Planning
Shaping
Hobbing
EDM

Two large, shiny metal machine shafts with gear-like ridges are lying parallel on a wooden surface in an industrial setting. Circular metal components are partially visible in the background.

Applications

Transmission Shafts
Drive Couplings
Gearbox Internals
Aerospace Actuators
Agricultural & Off-Highway Equipment
Robotics & Automation Components

A close-up of a cylindrical metal workpiece being machined on a milling machine, showing precise grooves and shiny surfaces created by the cutting tool.

Quality Assurance

All splines are machined and verified to international standards such as DIN 5480, ANSI B92.1, or per your custom specifications. Every part is inspected using calibrated gauges and pins, including plug and ring gauges, under our ISO 9001:2015 certified quality system.

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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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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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.