GEAR MANUFACTURING
With more than 100 years of gear‑cutting heritage and a production floor configured for wheels up to 10 ft Ø (3 m), Boundary delivers quality gearing for shovels, drills, mills and draglines operating in the world’s toughest mines.
Design & Optimisation
Reverse‑engineer worn or obsolete gears up to 120 in Ø using 3‑D scanning and AGMA/ISO simulation.
Material, geometry and heat‑treat tweaks extend service life under high‑impact, abrasive duty.
Collaborative engineering ensures compatibility with CAT, Komatsu, Hitachi and P&H machinery.
Machining
WFL M80 4500 Turn‑Mill Centre - rough‑and finish‑machines gear blanks up to 177 in L × 39 in Ø in a single setup, ensuring perfect concentricity before tooth cutting.
Additional horizontal & vertical CNC lathes handle forgings and castings to 216 in swing.
Cutting & Shaping
Our multi‑process cell cuts virtually any profile—spur, helical, double‑helical or internal ring.
Liebherr LC 1600 Hobbing Centre - dry/wet hob wheels to 63 in Ø with heavy‑duty modules.
Liebherr LS 2000 H Shaper - internal/external shaping to 78 in Ø at 1 DP pitch; ideal for dragline swing rings.
Gleason Pfauter P2400/2800H - external hobbing up to 118 in Ø for mill and kiln gears.
Grinding & Finishing
Gleason Pfauter P1200G grinder finishes gears to AGMA Class 15 accuracy (≤ 58 in Ø × 40 in face).
KAPP Niles & additional Pfauter grinders cover smaller modules down to 2 DP for propel and hoist pinions.
examples of past work
Got a drawing in hand?
Send it to our CNC team and let’s get the conversation started