At Direct Maintenance Services, we don't just rebuild gearboxes—we supply the gears that go inside them. By utilizing dedicated gear hobbing, shaping, heat-treating, and grinding processes, we eliminate the supply chain bottlenecks that keep your plant down.
From custom 8620 alloy steel double-helical extruder gears to massive cast iron cooling tower bevel gears, our metallurgical engineers and master machinists are on standby 24/7. We guarantee perfect tooth meshing, proper backlash clearances, and zero-defect runout.
When an OEM tells you a replacement gear is 16 weeks out, we manufacture it in days. We utilize state-of-the-art gear hobbing, shaping, and grinding equipment to deliver fast turnarounds.
High-capacity gear cutting for heavy-duty applications. Helical, spur, and worm gears cut to strict AGMA quality tolerances.
Corrects heat-treat distortion and provides an ultra-smooth finish, significantly reducing noise and vibration at high operating speeds.
Advanced laser scanning and spectrometry to exactingly recreate profiles from severely damaged or obsolete gears.
Internal ring gears, custom splined shafts, and keyway broaching for complex mechanical drives and sprockets.
Supplying replacement gears for heavy industrial gearboxes, pumps, extruders, and customized power transmission drives.
Straight-cut gears manufactured for heavy load applications, winches, and low-speed parallel shaft gearboxes.
Precision angled teeth for smoother, quieter, and stronger power transmission in high-speed industrial drives.
No-thrust double helical cutting perfectly mirrored to eliminate axial loads on heavy extruder drives.
Straight and spiral bevel gears specifically engineered for exact 90-degree power transmission.
High-ratio reduction gears. We cut bronze worm wheels and harden mating steel shafts.
Internal and external splines. Hardened, ground, and oversize-broached to restore worn tolerances.
Heavy-duty linear motion conversion components manufactured for extreme industrial actuation.
Deep-cut internal involute profiles for heavy planetary drives, swing gears, and centrifuges.
A gear's longevity is dictated by its material strength and surface hardness. We manage the heat-treating process to ensure maximum surface durability and core toughness.
Using Positive Material Identification (PMI), we analyze the exact chemical composition of your broken gear to match or upgrade the alloy (e.g., upgrading from 4140 to 4340 or 9310).
Creating a high-carbon, wear-resistant surface (case) while retaining a tough, shock-absorbing core. Ideal for heavy shock loads.
A low-temperature surface hardening process that introduces nitrogen into the steel, providing exceptional wear resistance without the thermal distortion of traditional quenching.
For applications requiring uniform strength throughout the gear tooth, we utilize precise quench and temper cycles to hit exact Rockwell (HRC) hardness targets.
Our zero-delay rapid turnaround process designed to get your custom gear cut and installed immediately.
Live gear specialist answers immediately - even holidays.
Hot-shot fleet dispatched to retrieve your broken sample.
3D laser mapping to reverse-engineer exact tooth profiles.
Continuous cutting on heavy-duty alloy blanks.
Precision finishing to correct heat-treat distortions.
Delivered back to your plant with guaranteed AGMA compliance.
Real machinist answers every call. Diagnosis and planning starts the second you contact us.
We retrieve your broken gears anywhere in the US and Canada. 100% free transport. Dispatched immediately.
We don't cut corners. Our gears meet or exceed original equipment manufacturer tolerances for load and speed.
We tightly manage the hobbing, shaping, grinding, and heat-treating processes to control the timeline. No waiting months for OEM replacements.
Yes. We only need a partially intact section of the gear to calculate the exact diametral pitch, pressure angle, and involute profile. Our engineers use CMM scanners to map the remaining geometry and interpolate the missing sections into a perfect 3D CAD model before hobbing begins.
We commonly upgrade OEM materials for better performance. We utilize high-grade alloy steels such as 4140, 4340, 8620, and 9310. For worm applications, we cast and machine high-strength manganese or aluminum bronze. We also handle specialized stainless steels and cast iron depending on the application's torque and speed requirements.
Line down? Gear stripped?
Don't wait weeks for OEM parts - we manufacture it bulletproof in days.
Email: INFO@DIRECTMAINTENANCESERVICES.COM
(832) 860-5493
