Regal Rexnord
Custom Gearing Solutions
Regal Rexnord custom gearing solutions encompass design - to - order and engineer - to - order gearboxes, open gearing sets, and specialty gear components manufactured to meet the specific torque, speed, dimensional, and environmental requirements of one - of - a - kind or limited - production applications that cannot be satisfied by standard catalog products.Under the Falk, Grove Gear, and Browning brands, our custom gearing group provides the engineering and manufacturing capabilities to produce large, high - torque gearboxes for steel - mill main drives, hydroelectric turbine speed increasers, marine propulsion reduction gears, and the custom open - gear sets that drive cement kilns, ball mills, and mining hoists.Plant project engineers and OEM equipment designers engage Regal Rexnord custom gearing when the application’s horsepower, shaft - center distances, ratio, or physical envelope exceed standard product offerings, or when the application requires specific material certifications, testing, or documentation packages for nuclear, naval, or classification - society regulatory compliance.Our process includes collaborative application engineering, advanced gear - design analysis(including finite - element tooth - contact and housing - deflection modeling), material selection with Charpy and ultrasonic verification, and full - load testing capabilities that validate the gearbox to its specified rating before shipment.
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Trusted by Industry Leaders
Unlimited Horsepower & Torque Sizing
Engineered to the specific power - transmission requirement — from hundreds to thousands of horsepower — using the appropriate gear geometry, bearing system, and housing design for a predictable, long - life design.
Application - Specific Center Distances & Ratios
Exact center - distance, ratio, and shaft orientations to match the existing machine geometry, eliminating expensive and compromise - prone adapter designs.
Full Material & Process Traceability
Materials sourced from certified mills, with documented chemistry, mechanical properties, and ultrasonic inspection for applications requiring nuclear, naval, or class-society documentation.
Advanced Lubrication & Cooling System Design
Integral pumps, oil coolers, filtration, and condition - monitoring sensors designed for the operating environment — enabling the gearbox to perform reliably in remote, high - temperature, or contaminated locations.
Reverse Engineering of Obsolete Components
When the original gearbox manufacturer no longer exists or supports the product, Regal Rexnord can reverse - engineer replacement gears and housings that fit the existing equipment without field modifications.
Full - Load Testing & Certification
Option for factory testing under controlled load, with measured efficiency, temperature, and vibration data documenting the gearbox’s performance against the design specification.
Custom Gearing for Steel Mill Drives, Kilns & Marine Reduction Gears
Cement kilns, ball mills, and steel rolling mills present some of the largest and most demanding gear - transmission challenges in industry — torques in the millions of foot - pounds, shock loads from process upsets, and continuous operation that makes reliability the highest - priority specification.Regal Rexnord custom gearing has designed and manufactured the main drive gears for hundreds of such applications worldwide, with gear diameters exceeding 30 feet, gear - tooth precision held to AGMA Class 12, and housing fabrications weighing tens of thousands of pounds.Marine propulsion reduction gears from Falk have powered U.S.Navy vessels and commercial ships for decades, meeting the shock - testing, quietness, and 100 % -power - continuous - rating requirements that define naval and classification - society specifications.Our custom gearing engineering team brings a century of accumulated application knowledge to each project, ensuring that the gear design reflects not just calculation but the practical lessons learned from thousands of installations.
The Custom Gearing Engineering & Manufacturing Process
Regal Rexnord’s custom gearing process begins with a detailed application specification — including the load spectrum, speed range, ambient conditions, and dimensional constraints.Our engineers develop a gear design that optimizes the tooth proportions, material selection, and bearing arrangement for the specified duty.FEA modeling verifies tooth - contact patterns and housing deflections under load.Manufacturing proceeds in our ISO - certified facilities, with in -process inspections at each stage — tooth - profile grinding with lead and involute chart documentation, material verification, and dimensional audits.For critical applications, assembled gearboxes are run under loaded conditions with measured vibration, temperature, and efficiency performance data provided to the customer.The result is a gear transmission system that meets the application’s specific requirements with the documented reliability that enables commissioning with confidence and decades of trouble - free operation.