Custom Plastic Gear Injection Molds
1.High-Precision Gear Tooth Geometry
Our custom injection molds for plastic gears are engineered with ultra-tight tolerances (±0.05mm) to ensure accurate tooth profiles, pitch circles, and pressure angles. Advanced wire EDM and gear hobbing techniques produce cavity inserts that replicate AGMA/ISO gear standards, delivering smooth meshing and consistent torque transmission.
2.Design Integration for Gear Performance
We mold in hubs, reinforcing ribs, bearing surfaces, and anti-backlash features directly into the gear. Multi-cavity configurations (2 to 16 cavities) enable high-volume production of spur, helical, bevel, and worm gears for automotive, robotics, and consumer electronics applications.
3.Durable & Reliable Production
Built from hardened tool steel (P20, H13, or D2), our molds deliver 500,000 to 1,000,000+ cycles with minimal wear on gear teeth. Optimized runner and gate placement ensures even cavity filling, reducing stress and distortion for long-running gear molding projects.
Custom Plastic Gear Injection Molds
1. Product Introduction
Our Custom Plastic Gear Injection Molds deliver precision tooling solutions for high-quality plastic gears. Gear molding demands extreme accuracy in tooth geometry, pitch diameter, and concentricity. Any deviation causes noise, vibration, premature wear, or system failure.
We design and build molds that produce gears meeting AGMA, ISO, or DIN standards. Each mold uses wire EDM or gear hobbing techniques for cavity manufacturing. The result: smooth meshing, efficient torque transmission, and extended gear life.
Our molds support spur gears, helical gears, bevel gears, worm gears, and internal ring gears. Applications include automotive actuators, robotics, power tools, medical devices, and consumer electronics.
2. Key Benefits
| Benefit | Description |
|---|---|
| Tooth Profile Accuracy | ±0.01mm tolerance on tooth geometry ensures proper meshing |
| Pitch Circle Precision | Precise cavity machining guarantees consistent center spacing |
| Design Integration | Molded hubs, ribs, bearing surfaces, and anti-backlash features |
| Multi-Cavity Output | 2, 4, 8, or 16 cavities for high-volume production |
| Wear Resistance | Hardened tool steel cavities (P20, H13, D2) deliver 500,000+ cycles |
| Cost Efficiency | Lower per-part cost through multi-cavity molds and fast cycles |
3. Gear Types We Mold
| Gear Type | Typical Applications | Mold Challenge |
|---|---|---|
| Spur Gear | Automotive actuators, printers, toys | Straight teeth, simple ejection |
| Helical Gear | Power tools, robotics, transmissions | Angled teeth require rotating core |
| Bevel Gear | Differentials, medical devices | Complex tooth geometry |
| Worm Gear | Steering systems, adjustable furniture | Undercuts, special ejection |
| Internal Ring Gear | Planetary systems, automotive | Internal teeth, core pulling |
4. Material Options
| Material | Key Properties | Best Applications |
|---|---|---|
| POM (Acetal/Delrin) | Low friction, excellent wear resistance, dimensionally stable | Most precision gears – our top recommendation |
| Nylon (PA6/PA66) | Tough, impact resistant, quiet operation | Automotive gears, power tools |
| Nylon + Glass Fiber | High strength, stiff, heat resistant | Heavy-load industrial gears |
| PBT | Good chemical resistance, low moisture absorption | Sensor gears, electronics |
| PEEK | Extreme temperature resistance, high strength | Aerospace, medical, high-performance gears |
5. Gear Cavity Manufacturing – Wire EDM & Gear Hobbing
Wire EDM (Electrical Discharge Machining)
A thin brass wire cuts the tooth profile using electrical sparks
Accuracy: ±0.005mm tooth profile
Surface finish: RA 0.4μm or better
Best for: Fine pitch gears, internal gears, prototypes
Gear Hobbing (for cavity inserts)
A rotating hob cuts the tooth form into hardened steel
Accuracy: ±0.01mm tooth profile
Surface finish: RA 0.8μm
Best for: High-volume production molds, coarse pitch gears
Quality Verification: Each gear cavity undergoes gear measuring machine inspection for tooth profile, pitch, and runout.
6. Ejection Methods for Gear Molds
| Ejection Method | Best For | Description |
|---|---|---|
| Ejector pins | Spur gears, straight teeth | Pins contact gear hub or web area |
| Stripper plate | Thin gears, delicate teeth | Plate pushes gear off core uniformly |
| Rotating core (unscrewing) | Helical gears, threaded features | Core rotates during ejection |
| Air ejection | Small gears, cosmetic surfaces | Compressed air blows gear off core |
Critical for helical gears: Our rotating core mechanism uses precision bearings and rack-and-pinion systems. The mold opens, the core rotates, and the gear unscrews without tooth damage.
7. Gate Placement for Gear Quality
Gate placement significantly affects gear quality. Poor gate location causes tooth distortion or weld lines.
| Gate Type | Best For | Effect on Teeth |
|---|---|---|
| Diaphragm gate | Precision gears | No weld lines on teeth – excellent |
| Pin-point gate (hub center) | 3-plate mold, cosmetic hub | No mark on teeth – very good |
| Edge gate on hub | Most spur gears | No mark on teeth – good |
| Edge gate on rim | Large gears | Possible tooth mark – not recommended |
Our standard recommendation: Diaphragm gate or pin-point gate on the hub center. This places no gate vestige or weld lines on the gear teeth.
Cavitation options:
| Cavities | Gear Diameter | Output per hour (30s cycle) |
|---|---|---|
| 1 cavity | Large (100–200mm) | 120 gears |
| 4 cavities | Medium (30–100mm) | 480 gears |
| 8 cavities | Small (15–30mm) | 960 gears |
| 16 cavities | Miniature (<15mm) | 1,920 gears |
8. Mold Steel Selection
Our recommendation: H13 for most production gear molds. D2 or powder metal for glass-filled materials or volumes exceeding 1 million cycles.
9. Common Gear Defects – Prevention
| Defect | Cause | Our Solution |
|---|---|---|
| Short shot | Poor gate sizing | Diaphragm gate ensures complete fill |
| Flash on teeth | Poor cavity/core fit | Precision ground mating surfaces |
| Weld lines on teeth | Multiple gates | Single gate on hub center |
| Tooth distortion | Uneven cooling | Conformal cooling around gear perimeter |
| Sink marks on hub | Thick hub section | Proper gate placement and rib design |
| Bore out-of-round | Uneven shrinkage | Optimized cooling and packing pressure |
10. Manufacturing Process & Quality Control
Mold Manufacturing Steps:
Gear design analysis (2–3 days)
Mold design and DFM (3–5 days)
Cavity machining – wire EDM or gear hobbing (1–3 weeks)
Core pin grinding (3–5 days)
Mold base machining (1 week)
Assembly and fitting (1 week)
Sample molding (2–3 days)
Quality Inspection Checklist:
✅ Tooth profile – CMM or gear measuring machine (±0.01mm)
✅ Pitch diameter – Within AGMA/ISO tolerance
✅ Runout – Less than 0.05mm
✅ Tooth thickness – Chordal or span measurement
✅ Hub bore concentricity – ±0.01mm
✅ Tooth flank surface finish – RA 0.4μm or better
11. Project Workflow
Step 1 – Gear Specification (3–5 days)
You provide: Gear 3D model, material, AGMA/ISO class, tooth count, volume
We provide: Mold concept, cavity count, firm quote
Step 2 – Mold Design (1–2 weeks)
Detailed 3D mold model, gate placement, ejection method, cooling design
Step 3 – Mold Manufacturing (4–8 weeks)
Cavity machining (wire EDM or hobbing), core pin grinding, assembly
Step 4 – Sampling (2–3 days)
Sample gears, gear measurement report, 20–50 samples shipped
Step 5 – Production or Delivery
Your approval, mold shipped with spare parts kit
Total lead time: 6–10 weeks
12. Technical Specifications
| Parameter | Range / Options |
|---|---|
| Gear type | Spur, helical, bevel, worm, internal ring |
| Module (metric) | 0.2mm to 4.0mm |
| Diametral pitch (imperial) | 120 to 6 |
| Gear diameter | 5mm to 300mm |
| AGMA quality class | Q5 to Q10 |
| Cavity count | 1, 2, 4, 8, 16 |
| Mold steel (cavity) | P20, H13, D2, powder metal |
| Cavity manufacturing | Wire EDM or gear hobbing |
| Gate type | Diaphragm or pin-point (hub center) |
| Ejection (spur gear) | Ejector pins or stripper plate |
| Ejection (helical gear) | Rotating core (unscrewing) |
| Cooling | Conformal around gear perimeter |
| Expected mold life (H13) | 500,000–1,000,000 cycles |
| Lead time | 6–10 weeks |
| Warranty | 12 months |
13. Why Choose Us
15+ years of gear mold manufacturing experience
In-house wire EDM and gear hobbing – complete quality control
Free DFM report – optimize your gear design before cutting steel
Rotating core capability – for helical and worm gears
Conformal cooling design – reduces cycle time, prevents distortion
Comprehensive gear inspection – CMM and gear measuring machine on-site
Competitive pricing – 20–30% lower than many competitors
Spare parts kit – ejector pins, springs, wear parts included
14. Request a Quote
Ready to produce high-precision plastic gears with a custom injection mold?
What we need to get started:
Gear 3D model (STEP, IGES, STP) or gear specifications (module/DP, tooth count, pressure angle)
Material type (POM, Nylon, PEEK, etc.)
Target AGMA or ISO quality class
Estimated annual volume
Special requirements (helical? rotating core? anti-backlash?)
What exactly are your OEM services?
Our OEM (Original Equipment Manufacturing) service allows you to bring your unique outdoor gear ideas to life. We handle the entire product development and manufacturing process based on your specifications, designs, and brand requirements. From initial concept and material sourcing to prototyping, production, and quality control, we become your dedicated manufacturing partner. Your brand logo and identity will be applied to the final products.What is your MOQ (Minimum Order Quantity)?
We understand that brands need flexibility, especially when launching new products. Therefore, we offer flexible MOQs, which vary depending on the product complexity, materials required, and customization level. We encourage you to discuss your project with us, and we will do our best to propose a feasible MOQ.Can you help us develop a product from just an idea or a sketch?
Absolutely! We specialize in turning concepts into high-quality, market-ready products. Our product development team will work closely with you to refine your idea, select appropriate materials, create technical drawings, and develop prototypes until your vision is perfectly realized.What are the typical steps in the OEM process with your company?
1.Initial Inquiry & Consultation: You share your concept, target market, and requirements. 2.Quotation & Agreement: We provide a detailed quotation, and once approved, we sign a service agreement. 3.Research & Development (R&D): Our team works on technical designs, material selection, and sample development. 4.Prototyping: We create a physical prototype for your evaluation and feedback. 5. Molds：After design confirming, we will creat mold before production. 5.Sample Approval: You approve the final sample, confirming quality, design, and functionality. 6.Mass Production: Upon your production order confirmation, we begin manufacturing your products. 7.Rigorous Quality Control (QC): We conduct inspections throughout production and a final random inspection before shipment. 8.Shipping & Delivery: We securely pack and arrange shipment to your designated destination.How long does the entire process take from concept to delivery?
The timeline varies significantly based on product complexity and order quantity. A general estimate is: Development & Sampling: 4-8 weeks. Mass Production: 4-6 weeks after sample approval. Please note that this is an estimate, and a precise timeline will be provided with your project quotation.Who owns the intellectual property (IP) and mold/tooling for the custom products?
You retain 100% ownership of your brand identity, designs, and product IP. For any custom molds or tooling created specifically for your project, ownership can be transferred to you upon agreement. We strictly adhere to confidentiality and will never use your designs for other clients.How do you determine the price for an OEM order?
The unit price is determined by several factors, including: Product complexity and design Cost of raw materials Labor and manufacturing processes involved Order quantity Packaging requirements We strive to offer competitive pricing without compromising on quality.What is your quality control process?
Quality is our top priority. Our QC process includes: Incoming Quality Control (IQC): Inspection of all raw materials. In-Process Quality Control (IPQC): Checks during key stages of production. Pre-Shipment Inspection (PSI): A final random inspection of finished products against your approved sample and our quality standards. We can provide detailed QC reports.Can we inspect the products before they are shipped?
Yes. We highly recommend a pre-shipment inspection. You are welcome to send your own QC inspector, or you can hire a third-party inspection company to perform the check at our factory. We can also provide you with photos and videos of the production and final products.How do you handle shipping?
We have extensive experience in shipping outdoor gear globally. We can handle the logistics for you and arrange shipment via sea (for large volumes) or air (for smaller, urgent orders). We work with reliable freight forwarders to ensure a smooth process. Shipping costs will be included in your final quotation.
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