For decades, precision gear production has relied on highly specialised machines and dedicated tooling, limiting flexibility, increasing costs and restricting innovation. Dontyne Gears is challenging that model through a combination of advanced software and an Okuma Genos M460V-5AX machining centre supplied by NCMT.

The company’s objective was to develop software capable of generating machining strategies and NC code directly from gear design data, enabling complex gears to be produced on a standard five-axis machining centre using readily available tooling. The Okuma Genos M460V-5AX provided the platform required to turn that vision into reality.

“The machine gave Dontyne the flexibility and precision needed to validate its software,” says Andrew Skee, sales manager at NCMT. “It demonstrates that aerospace-level accuracy and repeatability can be achieved on a versatile machining platform rather than dedicated gear-cutting equipment.”

According to Dr Michael Fish, director of Dontyne Systems, the machine has transformed the company’s ability to prove and refine its technology: “Having the Okuma machine in-house allowed us to validate our software on real components. We can generate machining code for complex gear forms in seconds and, with integrated Renishaw Sprint measurement technology, verify results directly on the machine. After extensive development work, we are often achieving ISO 4-5 gear quality on the first attempt.”

Dontyne’s Gear Production Suite creates a digital twin of a gear design, automatically generating manufacturing and inspection data. The system has successfully produced a wide range of gear forms, including spiral bevels, hypoids, helicals and internal gears, all on a single five-axis platform.

Supported by research funded through the British Gear Association, the project is demonstrating that complex gears can be produced more quickly, economically and flexibly than traditional methods.

More information www.ncmt.co.uk