This is a custom double bevel gear machined from PEEK. It has two bevel gears on a single shaft, one at each end, with a hexagonal bore through the top gear and a hub at the base. Both gears and the shaft were machined from one piece of solid PEEK.

The part was machined from solid natural PEEK. PEEK is a high-performance engineering plastic. It handles continuous service around 250°C, resists a wide range of chemicals, insulates electrically, and runs with low friction and good wear resistance without added lubrication, which is what lets a plastic gear work well. A PEEK gear runs quieter and lighter than a metal one and needs no lubrication, which suits drives where a metal gear would be noisy, would need lube, or can’t be used because of corrosion or electrical concerns. Machining the gear from solid stock, rather than molding it, lets us hold the tooth form and the bore accurately on a one-off or low-volume part without the cost of a mold. Where more strength or stiffness is needed, we also machine GF-PEEK or CF-PEEK.

Part type:  Custom Double Bevel Gear (two gears on one shaft)

Material: PEEK

Machining Process: CNC Turning + CNC Milling

Surface Finish: As-machined, Deburred

Side view of the PEEK double bevel gear, showing the two bevel gears machined on one shaft.

We turned the shaft, the hub, and the round bodies of the two gear blanks first, and cut the hexagonal bore through the top. Then the bevel teeth were machined on both angled faces, one gear at each end. The teeth are the hard part of this job. On a bevel gear the teeth sit on a cone and change size along their length, so cutting them accurately takes multi-axis machining and careful tool paths. With two gears on one part, both sets have to be cut accurately and stay concentric to the same axis, so the part runs true. We referenced the teeth, the bore, and the hub all to the same center.

The part was left as-machined in natural PEEK, with the teeth, bore, and edges deburred. Before shipping we checked both sets of teeth, the hex bore, the concentricity of the two gears to one axis, and the overall dimensions against the drawing. The result is a one-piece double bevel gear that fits its hex shaft and meshes correctly with its mating gears at both ends. Because it’s machined from solid to a set process, the same gear can be reordered in any quantity without tooling cost, which suits prototypes and low-volume runs where molding wouldn’t be worth the mold.

We provide custom CNC machining services for low-volume production and rapid prototyping for design verification.  Click Here to Upload Your CAD Files