It is a common occurrence for us to manufacture new press gears, we make dozens each year. Sometimes it’s because of broken gear teeth, excessive wear/backlash or in some cases, due to a press modification or upgrade. Most of our large gears are fabricated in house to specifications that exceed industry standards. However, sometimes we find that manufacturing from a solid alloy forging is the best way to create a superbly rigid, balanced and undeniably heavy duty press gear. These forgings are upset, pierced, and rolled for optimum grain structure, then machined on our CNC lathes with generous radii to eliminate the stress risers commonly found in welded gears. Keyless connections are used whenever possible to further eliminate stress risers and ease assembly. While this option may be overkill for some applications, it can often be manufactured faster than fabrication. Shown here are several examples of new (intermediate & bull gears) machined from solid forgings. These were all instances where premium gears were the best solution.