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Custom CNC Machined PEEK Gears

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Two custom CNC machined virgin PEEK spur gears with a counterbored hub, demonstrating burr-free involute tooth profiles.

This project involved replacing 316L stainless steel gears in a chemical dosing pump system. The metallic gears were experiencing premature failure due to galvanic corrosion and galling when running in dry or semi-dry conditions. Virgin PEEK was selected as the replacement material due to its exceptional chemical resistance, inherent self-lubricating properties, and high mechanical fatigue strength.

Because the manufacturing routing requires two separate machine setups—a lathe for the blank and a mill for the teeth—managing the datum transfer is critical. Any runout introduced during the second setup will result in uneven tooth loading and premature transmission failure. Additionally, the poor thermal conductivity of unfilled PEEK causes localized heat buildup during tooth milling, leading to thermal expansion and distortion of the involute profile.

Project Details

Part type: Custom PEEK Gears

Material: Virgin PEEK

Machining Process: CNC Turning, 5-Axis CNC Milling

Surface Finish: As-machined

Quantity: 300 pcs

Lead Time: 20 day

Our CNC Machining Process

Custom CNC machining PEEK gear process. A 5-axis milling center utilizing a solid carbide end mill to generate the involute tooth profile on a turned virgin PEEK blank.

5-axis CNC milling of the PEEK gear teeth. The previously turned blank (Datum A) is securely mounted on the rotary axis. Continuous path milling and targeted coolant application are utilized to prevent polymer thermal distortion during the cut.

To maintain the required AGMA quality class, we processed these custom CNC machined PEEK gears using a rigidly controlled 3-stage operation:

  • Phase 1: Precision CNC Turning (Blank Preparation): The extruded PEEK rod was first machined on a CNC lathe. This stage establishes the primary datum (Datum A): the central bore and the counterbored hub. Holding a tight tolerance on the bore diameter at this stage is essential, as it serves as the locating feature for the subsequent milling operation.
  • Phase 2: 5-Axis CNC Milling (Tooth Generation): The turned blanks were then transferred to a 5-axis CNC machining center. To eliminate runout during this setup change, the blanks were mounted utilizing precision-ground expanding arbors that reference the turned bore (Datum A). The 5-axis platform then utilized synchronized continuous toolpaths to mill the involute gear teeth relative to the true center of the part.
  • Phase 3: The completed custom CNC machined PEEK gears were subjected to dimensional inspection. The central bore concentricity to the pitch diameter was verified using a CMM, and the tooth flank surface finish was confirmed to be smooth and free of machining marks, ensuring low-friction power transmission in the final pump assembly.

Free Quote & Design Review

Our engineers are experienced in machining advanced polymers, including unfilled PEEK, Ultem (PEI), Torlon (PAI), and PTFE. We provide custom CNC machining services for low-volume production and Rapid Prototyping for design verification.  Click Here to Upload Your CAD Files

Our Manufacturing Capabilities

5-axis CNC milling machine cutting an aluminum block during the manufacturing process.

Capabilities include 3-Axis, 4-Axis, and 5-Axis CNC Milling, as well as CNC Turning operations. Standard materials processed include Aluminum alloys, Stainless Steel, Titanium, etc. and Engineering Plastics. Available secondary operations include Anodizing, Powder Coating, Bead Blasting, and Laser Engraving.

Capacity supports requirements ranging from single-unit Rapid Prototyping to Low-Volume Production runs (1-1,000+ units).

Factory Quality Assurance

A highly accurate ZEISS Coordinate Measuring Machine (CMM) inspecting the internal dimensions and tight tolerances of a custom CNC machined component.

A standardized Quality Management System (QMS) is applied to all manufacturing orders, regardless of part complexity or production volume. The following inspection stages are mandatory for every CNC machining project:

  • Material Verification: Raw material certification (chemical composition and mechanical properties) is verified upon receipt to ensure compliance with material specifications.

  • First Article Inspection (FAI): The first unit from any production run undergoes a full dimensional report to validate the machining setup and programming before volume processing begins.

  • In-Process Monitoring: Periodic checks are conducted during the machining cycle to monitor tool wear and ensure dimensional consistency is maintained throughout the batch.

  • Final Inspection: Completed components undergo a final dimensional and cosmetic verification using CMM (Coordinate Measuring Machine) and calibrated manual instruments prior to packaging.

Order Fulfillment Process

Finished CNC machined components securely packaged in custom foam inserts for global shipping.

From CAD to part.

Step 1: Upload & Quote

Upload your CAD files (STEP/IGES) to our secure platform. Receive a detailed online CNC quote and lead time estimate within 24 hours.

Step 2: Free DFM Review

Our engineers conduct a Design for Manufacturability (DFM) analysis to optimize your design for rapid machining and reduce costs.

Step 3: Precision Machining

We ensure your custom CNC parts meet strict tolerance requirements.

Step 4: Quality Control

Every part undergoes rigorous inspection before leaving our factory to ensure it matches your specifications perfectly.

Step 5: Fast Delivery

We partner with DHL/FedEx for global express shipping. Get your CNC prototypes delivered to your door in as fast as 7 days.

FAQs About CNC Machining Services

No. We support projects of all sizes, from a single prototype unit to low-volume production runs.

Standard lead times are typically 10–15 business days. Expedited services (Rapid Prototyping) can be completed in as little as 3–5 business days, depending on part complexity and material availability.

In most cases, we source materials from our approved suppliers to ensure quality control. However, we can machine customer-supplied materials for specialized alloys or specific requirements upon engineering review.

Unless otherwise specified, our general tolerance standard is ISO 2768-m (±0.125 mm) for metals and ±0.25 mm for plastics. Precision tolerances ±0.005 mm are achievable but must be explicitly stated in 2D technical drawings.

Our facility can accommodate parts up to 4000 x 1500 x 600 mm for milling and Ø200 mm x 500 mm for turning.

Yes. We can install inserts (e.g., Helicoils, PEM fasteners) and perform basic mechanical assembly of machined components prior to shipment.

To provide an accurate quote, we require a 3D CAD file (STEP, IGES, or X_T format). If the part has threaded holes, tight tolerances, or specific surface finish requirements, a 2D PDF drawing must also be provided.

We take IP protection seriously. All files are stored securely, and we are willing to sign a Non-Disclosure Agreement (NDA) prior to receiving your data.

Yes. We can provide material certificates (COA) and dimensional inspection reports upon request. Please specify this requirement when placing your order.

We ship globally using major carriers (DHL, FedEx, UPS).

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