Longsheng

At LS, we know that in today's competitive environment, cost control and speed of delivery are the key to success. Especially in complexgear manufacturing processes, we are committed to providing our customers with efficient andhigh-quality gear processing,3D printing,prototype productionand other services designed to help gear compan and achieve a 30% cost reduction while accelerating product delivery. We rely on advanced technology, professional teams and rigorous management to ensure we create more value for our customers while maintaining high quality products. Next, let's look at how LS can do that.

How can we ensure that we reduce costs without sacrificing product quality?

LS companycan achieve this by precisely controlling thegear manufacturing process design. We carry out in-depth research on every part of the gear manufacturing process and are committed to using advanced technology and equipment to verify the most optimal manufacturing accuracy and performance of the gear before any components are manufactured.

At the same time,we have an experienced and skilled teamthat utilizes a combination of topology optimizationalgorithms and additive manufacturing techniquesto maximize material utilization. Using data instead of experience, the AI adaptive cutting system is combined with online monitoring to improve productivity. The laser cladding gradient functional coating is used to treatthe gear surface, which not only maintains the stability and reliability of gear quality, but also reduces warranty costs. In addition, we maintain close communication with our customers to keep abreast of their needs and feedback in order to continually adapt and improve our products and services to ensure that we always meet their expectations.

Can the customized services provided by LS company meet the specific cost reduction and delivery needs of customers?

In gear manufacturing process, LS company deeply integrates digital design with intelligent manufacturing tocustomize gear manufacturing solutionsfor customers in different industries, effectively balancing cost control and delivery efficiency. Core measures include an AI based parameterized gear design platform that generates the most tooth profile toothed solution in 15 minutes, reducing trial and error costs Deploy deploying fully automated production lines that compress unit processing times over 40% percent; and increasing response times to customer order changes 60% percent through supply chain collaboration network network.

In addition, dry cutting and surplus material recycling system have reduced energy consumption by 30% and material waste by 78%, respectively, helping customers achieve a 30% reduction in single-gear costs and a 50% reduction in delivery cycles. These measures have been successfully applied tonew energy vehicles, wind power and so on, validating the feasibility of their customization services in the areas of precise cost reduction and agile delivery.

Case 1：Transmission Gear

LS Company Helps European Car Companies Achieve Large ScaleTransmission GearCost Reduction and Efficiency Increase.

Company Name:LeadingAutomotive partssupplier in Europe.

Scope:Research and development and production ofAutomobile gearbox geardevelopment and production of gearbox gears.

Annual production capacity requirement:500000 pieces (matching high-end models).

Core pain points:

• Traditional manufacturing costs high: 65 per unit, material waste.
• Long lead time: 8 weeks from order to delivery, difficult to meet the urgent needs of the host factory.
• Low yield: Only 85%, high waste repair costs.

LS Company Solution

LS Company offers end-to-end solutions through a combination of process reconstruction+equipment upgrade+intelligent management:

1. Gear Manufacturing Process:High Speed Gear Roller + hobbing+ integrated vacuum heat treatment

Process innovation:

• High-speed tooth rolling technology: the use of cemented carbide tools, processing speed to double the traditional process (200m/min → 400m/min), single piece processing time reduced by 40%.
• Vacuum heat treatment: replaces traditional salt bath quenching, reduces oxidation deformation, improves gear surface hardness to HRC58-62, and improves abrasion resistance by 30%.

Data comparison:

Process parameters	Traditional crafts	LS optimization process	Increase amplitude
Processing time/piece	2.5 minutes	1.5 minutes	40%↓
Surface roughness (Ra)	1.6μm	0.8μm	50%↓

2. Equipment upgrade: 5-axis CNC all-weather production

• Hardware investment: Configuration of5 five-axis interlocking machiningcenters to support one-off molding of complex tooth profiles.
• Intelligent transformation: Integration of adaptive control system,real-time adjustment of cutting parameters(such as speed, feed rate, etc.), equipment utilization rate rate increased to 92% (industry average 75%).
• Capacity improvement: From 80 units per day to 120 units per day, with an annual capacity of 600000 pieces (meet customer demand of 500000 pieces, with redundancy reserved).

3. Quality control: full process digital closed-loop

• The first test rate of on-line optical measurement equipment (accuracy ± 0.005mm) was 100%.
• X-ray nondestructive testing (XNDT) is used to detect internal defects, and the yield rate increased from 85% to 98%.

4. Cost Structure Comparison Table

Cost items	Traditional model ($/piece)	LS scheme ($/piece)	drop
Cost of materials	25	18	28%↓
Equipment depreciation	8	7	12.5%↓
Energy consumption	5	3	40%↓
Waste loss	7	1	85%↓
Total cost Total	45	31	​31%↓

5. Implementation effectiveness

Index	Traditional model ($/piece)	LS scheme ($/piece)	Increase amplitude
Unit cost	$65	$46.8	​28%↓
Material costs	$25 (utilization rate of 70%)	$18 (utilization rate of 85%)	28%↓
Labor costs	$18 (dependent on skilled workers)	$9 (Automated Processing)	50%↓
Delivery cycle	8 weeks	5 weeks	​37.5%↓
Yield rate	85%	98%	​15.3%↑
Annual cost savings	-	$1,200,000	-

• Customer testimony

LS Company's solution not only reduced the cost of producing our gearbox gears by 28%, but also increased yield rate to a record 98%. Through 5-axis CNC machining and vacuum heat treatment technology,the gear strength and lightweight dual breakthroughs have been achieved, and the assembly efficiency of the host factory has been significantly improved.

Case 2: Micro scale Gears

LS Company helps US robotics partner achieve mass production of Micro scale Gears.

Company name:Acollaborative robotstartup the the United States

Business requirements:Development of high-precisionmicrogears for robotic arm joints(0.3 module, ≤ 10mm in diameter).

Core pain points:

• Insufficient accuracy: The existing supplier's gear tolerance is ± 10 μ m, far higher than the the required ± 5 μ m.
• Too many minimum order quantity:Traditional suppliers require 5,000 MOQs, start-ups just 100 prototypes.
• Delivery delay: Traditional processes require up to 12 weeks to ship, delaying product launch.

LS Company Solution

LS company solved the production problems in the manufacture of micrometer level by Swisslathe technology+ real-time quality control + flexible manufacturing system:

1. Precision machining technology: Swiss Laundry

• Equipment choice: Swiss styleCNC lathe(Tornos Deco 2000) with high-resolution encoder (± 0.5 μ m).
• Processing parameters:

Parameter LS Process Standard	LS process standard
Spindles 12000 RPM rpm	12,000 RPM
Feed rate 0.02 mm/ year	0.02 mm/r
Cooling method: Micro lubrication (MQL)	Micro lubrication (MQL)

• Accuracy verification:

Testing Index	LS process standard	Actual measurement mean
FPK	≤±5μm/10mm	±3.2μm
Gear ring radial runout	≤2μm	1.5μm

2. Real-time quality control: Online detection system

Testing process:

• machine measurement:gear tooth profile dataare collected in real time the machining process.
• Adaptive compensation: Adjust tool wear error by algorithm to ensure batch consistency.

Data comparison:

Size of detection	Traditional process error margin	LS process error range
Tooth profile	±15μm	±5μm
Surface roughness (Ra)	0.8μm	0.4μm

3. Flexible production mode:Small batch fast iteration supported

• Prototype stage:Minimum order of 100 pieces delivered within 7 days (traditional 30 days);
• Mass production phase: Modular fixture switching with changeover time ≤ 15 minutes;
• Cost comparison analysis:

Unified supplier:

Price per unit: 50 pieces x 100 pieces = $5,000

Emergency costs (shortened to 30 days):+$2,000

Total cost: $7000

LS scheme:

Unit price: 60 pieces x 100 pieces= $6000

There is no rush charge, a total saving of $1000.

4. Implementation effectiveness

Index	Traditional suppliers	LS Company Plan	Increase amplitude
Tolerance control	±10μm	±3μm	​70%↑
Delivery cycle	12 weeks	3 weeks (prototype)	​75%↓
Noise level	65 dB	39 dB	​40%↓
Durability	50000 cycles	100000 cycles	​100%↑
Total cost	$25000 (5000 pieces)	$6000 (100 pieces)	​76%↓

• Customer Testimony

For the first time, LS company's Swiss turning technology enables us to achievegear accuracy of ± 3 μmwith a minimum displacement of 100 slices.From prototype to mass production, it took only 3 months to hit the market 6 weeks early and garnered a $2 million order.

Case 3:Industrial Gearboxes

LS Company helps German manufacturers achieve Industrial Gearboxes.

Company name:German manufacturer ofhigh-end industrial gearboxes(Top 10 in global market share).

Business field:Wind farms gearbox, mining machinery transmission.

Core requirements:Development of a new generation of high torque gearboxes (rated torque ≥ 200 kN· m) that meet IP67 protection level and work with wide temperature differences of -40 ° C to 80 ° C.

Core challenges:

• Traditional process cost is high: adopting casting steel + rough processing + heat treatment process, the waste rate of single piece material is 25%%, the processing energy consumption is 30% of the cost.
• Long lead time: 18 weeks from blank to assembly, unable tomeet customers' urgent order needs.
• Reliability risk: fatigue life on tooth surface is only 10 cycles (industry benchmark is 10 cycles).

LS Company Solution

LS reconstructs the gearbox manufacturing value chain through the Powder Metallurgy Near Net Forming +Multi-Axis Intelligent Processing+ Life Prediction Model technology:

1. Material and process innovation: Powder metallurgy reduces costs by 30%

Technical Path:

• Near-mesh forming Powder metallurgy: Using titanium hydroxide alloy powder (TiH2),gear blankswas prepared directly by compression molding and sintering process, and material utilization rate increased from 65% to 92%.
• Gradient heat treatment: The grain size is controlled at 50-150 μ m by optimizing the sintering temperature curve by DSC curve, increasing the strength by 20%.

Data comparison:

Process indicators	Traditional cast steel parts	LS powder metallurgy parts
Material density (g/cm ³)	7.85	6.92
Fatigue life (times)	10⁷	1.2×10⁸
Processing energy consumption (kWh/piece)	180	95

2. Intelligent manufacturing: Full process digitization, efficiency

Process Re-engineering:

• Traditional process: Rough casting → rough turning → heat treatment → precision machining → assembly (18 weeks)
• LS process: Powder pressing → sintering →five axis CNC forming→ online detection → intelligent assembly (9 weeks)

Key Nodes to Efficiency:

• Axle linkage machining: One processing to complete 12 processes such as tooth groove, keyhole, oil hole processing time reduced from 72 hours to 18 hours.
• Adaptive cutting parameters: Dynamic adjustment of feed speed according to cutting force model, tool life increases threefold.
• Parallel heat treatment: carburizing technology is used the sintering furnace without the need for a separate heat treatment process.

3. Digital twins and lifespan expectancy

• FEA fatigue analysis: ANSYS Workbench was used to simulate gear meshing conditions,optimize tooth profile parametersand reduce surface contact stress from 1200MPa to 850MPa.
• Artificial Intelligence (AI) life prediction: Models trained on 100000 sets workstate data were 92% accurate in predicting potential design defects three months in advance.

4. Breakdown of cost structure

Cost project	Traditional cost ($/piece)	LS cost ($/piece)	Drop
Material procurement	680	450	33%↓
Processing energy consumption	270	75	72%↓
Labor cost	150	60	60%↓
Waste loss	120	5	95%↓
Total cost	1220	630	​48%↓

5. Implementation effectiveness

Index	Traditional mode	LS scheme	Increase amplitude
Unit cost	$2,100	$1,575	​25%↓
Delivery cycle	18 weeks	9 weeks	​50%↑
Yield rate	88%	99.5%	​13%↑
Energy consumption intensity	0.15 kWh/ton	0.08 kWh/ton	​50%↓
Market response speed	Starting from 6 months for ordering	Starting from 2 weeks for ordering	​90%↑

• Customer Testimony

The lump sum The powder metallurgy process not only reduces the cost of the gearbox by 25%, but also enables us to provide reliability verification reports at the bidding stage through digital twin technology. Last year's emergency delivery of 300 Taiwan Straitwind power gearboxeshas been over 200000 hours of continuous trouble-free operation, customer renewal rate increased to 95%!

What are the core advantages of LS based on the above case studies?

The core strength of LS is itstechnology empowerment + full process digitization gear manufacturing model, especially the depth of support forDIY gears requirements. Customers can upload design parameters independently, obtain feasible solutions of 3D printing and five-axis processing in real time, andrealize one-stop rapid iteration from concept to prototype.

In addition,LS company serves customers around the worldby supporting quick delivery on small orders (up to 7 days for prototypes), allowing customers the flexibility to control production pace and ensure gear accuracy (± 3 μM) and reliability in line with industry standards. This service model is the core barrier LS company to stand out in the global gear market.

Summary

LS company reshaped the traditional gear manufacturing pattern with its advanced gear manufacturing processes. Focusing on technology-driven, cost-controlled core businesses such ashigh-precision machining, rapid prototyping andmass customization, the company has successfully addressed the complex challenges facing its customers in the automotive andindustrial sectors. These success stories represent the core value of LS in gear manufacturing process design innovation. Replace experience dependence with technology-driven solutions, meet customization needs with flexible production, and ultimately create solutions that combine cost advantages and breakthroughs in performance for our customers.

Disclaimer

The content on this page is for reference only.LSdoes not make any express or implied representation or warranty as to the accuracy, completeness or validity of the information. No performance parameters, geometric tolerances, specific design features, material quality and type or workmanship should be inferred as to what a third party supplier or manufacturer will deliver through the Longsheng Network. It is the responsibility of the buyerseeking a quote for partsto determine the specific requirements for those parts.Pleasecontact usfor moreinformation.

LS Team

LS is an industry-leading companyspecializing in custom manufacturing solutions. With over 20 years of experience serving more than 5,000 clients, we focus on high-precisionCNC machining,sheet metal fabrication,3D printing,injection molding,metal stamping,and other one-stop manufacturing services.
Our factory is equipped with more than 100 advanced 5-axis machining centers and is ISO 9001:2015 certified. We provide fast, efficient, and high-quality manufacturing solutions to customers in over 150 countries worldwide. Whether it’s low-volume production or large-scale customization, we can meet your needs with delivery as fast as 24 hours. ChoosingLS Technologymeans choosing efficiency, quality, and professionalism.
To learn more, please visit our website:www.lsrpf.com

FAQs

1.Does LS company provide technical support and after-sales service?

We provide comprehensive technical support and after-sales service, including equipment installation and commissioning, operation training, maintenance, etc., to ensure that customers receive timely and effective assistance during use process.

2.How does LS company manage priority delivery of emergency orders?

Digital scheduling system support rapid response of 10 to500 items in a single batch, and emergency order priority algorithm increase delivery speed by 90%. A certain car customer's urgent order will be placed within 7 days to seize the market opportunity.

3.How does LS company implement rapid prototyping of custom gear?

SLA rapid prototyping technology delivers prototypes within 7 days and supports design iterations. A research institute has shortened the R & D cycle by 64% and the cost by 50% by trialling 3D printing.

4.How does LS company's powder metallurgy process achieve gear lightweighting?

The near-net-forming process of hydrogenated titanium alloy powder reduces density to 6.92g/cm, reduces weight by 50% and maintains high strength. A certain robot customer's gear set reduces energy consumption by 40% and greatly improves battery life.

Resources

Gear manufacturing

Automated manual transmission

Sequential manual transmission