HOME NEWS MECHANICS IN PILLS Rebuilding a Sun Gear Without a Drawing: How to Restore an Unavailable Component

Rebuilding a Sun Gear Without a Drawing: How to Restore an Unavailable Component

maggio 28, 2025
Have you ever faced downtime because of a single missing part, with no technical drawings and no replacement on the market?

Rebuilding a sun gear without a drawing is a complex challenge—but entirely manageable with the right expertise and tools. Recently, GSI Ingranaggi successfully tackled such a case, restoring a planetary gearbox through an advanced reverse engineering process.

Rebuilding a Sun Gear Without a Drawing: The GSI Process

  1. Original Material Analysis: We use a spectrometer to precisely determine the chemical composition of the material, ensuring the new sun gear matches the original's mechanical properties.
  2. Heat Treatment Identification: Through hardness testing and metallographic analysis, we identify the type of heat treatment (such as carburizing or quenching) to replicate the component's original behavior.
  3. Complete Geometric Survey: We perform a full mapping of the component using advanced instruments and specialized software:
  • Determining module, number of teeth, and pressure angle
  • Verifying any profile corrections
  • Measuring the Wildhaber curve to ensure precision and proper meshing
   4.  Creation of the Technical Drawing: Based on the collected data, we internally develop 2D and 3D technical drawings, redesigning the component to preserve its original functional characteristics.
   5. Manufacturing and Validation: We build the new sun gear and subject it to strict dimensional and functional checks, ensuring it's ready for installation and operation.

The Result

The customer was able to restore their gearbox without replacing the entire system. A precise, quick, and sustainable intervention—carried out without any original documentation.

At GSI Ingranaggi, we’ve been supporting our customers for over 50 years not only in prototyping and batch production, but also in complex cases like this, where experience, technical intuition, and advanced measuring tools make the difference.

If you're facing a similar issue, contact us to find out how we can help you get your machinery back in operation.

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    GSI Ingranaggi S.r.l.
    Via S. Quasimodo, 9 - 42023
    Cadelbosco Sopra (RE)

    Tel. +39 0522.917750 / 917365
    E-mail gsi@gsi-ingranaggi.it


    © 2025 GSI Ingranaggi S.r.l. - Via S. Quasimodo, 9 - 42023 Cadelbosco Sopra (RE) - P.Iva 00211250352 - NUM. REA RE-110195 - PEC: gsisrl@gigapec.it - gsi@gsi-ingranaggi.it
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