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  Custom Gear Manufacturing

DESIGN I BUILD TO PRINT I PROTOTYPE TO PRODUCTION

CUSTOM GEAR SOLUTIONS

Precision Gears, Mechanical Components, & Assemblies

SDP/SI is a leading manufacturer of precision gears, mechanical components, and complex gear assemblies, serving top names in the aerospace, medical, and robotics industries. With all engineering and manufacturing performed in-house, we ensure complete control over quality, lead times, and responsiveness to customer needs.

From initial design to full-scale production, our team supports every stage of development—offering valuable insights backed by over 75 years of gear manufacturing expertise. This collaborative approach often leads to streamlined, lightweight, and cost-effective solutions with improved manufacturability and performance.

Collection of Custom Gears
Collection of Custom Gears

At SDP/SI, we specialize in high-quality custom gear manufacturing, creating precision gears, machined components, and assemblies tailored to your exact specifications. We offer a wide variety of gears, including bevel, anti-backlash, helical, miter, worms, racks, pinions, planetary systems, plastic gears, gearboxes, speed reducers, differentials, and custom shafting.

Our services include precision turning (from 1/8" to 8" diameter) and milling (up to 8" x 20"), with gear cutting capabilities ranging from 16DP to 200DP (modules 0.5 to 3) and worms from 16DP to 72DP, all with tolerances as tight as +/- .0001". We also provide custom shafts, ranging from 1/32" to 1-1/2" in diameter, with tight tolerances and straightness up to .0003" per inch.

We work with a wide range of materials, including aluminum, stainless steel, nylon, and titanium, and offer various plating options—such as zinc, chrome, and nickel—as well as anodizing, all performed in NADCAP- and customer-approved facilities. Additionally, we provide mechanical assembly services in an ISO 7 certified cleanroom, maintaining strict control over airborne particles, airflow, and environmental conditions to ensure minimal contamination.

Investing in the World’s Finest Manufacturing Equipment

SDP/SI is committed to continuous improvement, reinvesting in our Hicksville, NY facility to stay at the forefront of gear manufacturing technology. With over 170 machines—including CNC bevel gear cutters, gear hobbing and shaping equipment, Coniflex bevel gear generators, and rack cutting machines—we ensure gear teeth are cut to exceptionally tight tolerances with consistent precision. Our ongoing investments in advanced machinery and tooling reflect our dedication to quality and innovation.

Discover how our gear-cutting capabilities can support your next project.
Download our facility list or contact us to discuss your requirements.

Custom Gears with Hubs

Key Application Areas:

Medical:

  • Surgical Robots
  • Minimally Invasive Surgical Gear Drives
  • Precision Pumps & Drives
  • Drug Delivery Systems
  • Pharmaceutical Processing & Packaging Equipment

Aerospace & Defense:

  • Actuation & Positioning Systems
  • Satellite Solar Wing Positioning
  • Door & Hatch Release Mechanisms
  • Fuel Control Systems
  • Stabilization & Guidance Systems
  • Antenna & Sensor Positioning
  • Weapons Targeting Platforms

Robotics & UAVs:

  • Autonomous Navigation
  • Motion Control Systems
  • Precision Drive Mechanisms

Our solutions are deployed in mission-critical systems across medical, aerospace, defense, and commercial sectors. From surgical precision to advanced defense platforms, our components deliver reliable performance in the most demanding environments.

Spur Gears

Spur gears are the most commonly used gear type, designed to efficiently transmit power and motion between parallel shafts. Depending upon the number of teeth on the driving gear, they can be used to increase or reduce drive speed. SDP/SI manufactures precision spur gears for custom gear trains, speed reducers, gearboxes, and planetary gear sets.

We produce spur gears, internal spur gears, and cluster spur gear assemblies in both metal and plastic, tailored to your specific requirements. Internal spur gears are precision-machined to mate seamlessly with external spur gears, while cluster gear assemblies are engineered for reliable performance in both low- and high-torque applications.

Looking for a custom spur gear solution? Contact us to discuss your application or request a quote.

Two Steel Custom Gears
Two Steel Custom Gears

Precision Gear Solutions for Aerospace and Defense

SDP/SI is a trusted manufacturer of custom planetary gearboxes and assemblies for aerospace and defense. Our in-house engineering and manufacturing teams work closely with your design group to deliver high-performance, reliable gear systems—taking your concept from prototype to production. Our gear assemblies are used in mission-critical functions, including wing positioning, door actuation, fuel systems, instrumentation, and steering mechanisms.

As an AS9100-certified company, we meet stringent aerospace quality standards. Our components are found in aircraft, missiles, and satellites worldwide, with customers including Boeing, GE Aviation, Israel Aerospace, Kearfott Guidance, Lockheed Martin, NASA, and Raytheon, to name a few.

With decades of experience and a commitment to precision, SDP/SI is your partner for advanced motion solutions.

Custom Gears

Precision CNC Machined Components for all Applications:

Since 1950, SDP/SI has delivered high-quality stock and custom mechanical components, serving industries that demand precision and reliability. Beyond manufacturing parts, we design, machine, and assemble custom subassemblies built to exacting standards for virtually any application.

As specialists in precision gears and small mechanical components, we offer a full range of advanced machining capabilities, including CNC Swiss turning, CNC milling, gear hobbing, CNC gear grinding, gear shaping, bevel and helical gear cutting, gear inspection, and full gear design support.

Browse our full line of stock gears, mechanical components, and molded parts online at sdp-si.com — complete with product specs, technical data, and 3D CAD models.

Have a drawing or CAD file? We’ll quote it. For design reviews or questions, call (516) 328-3300 or send an RFQ today.

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