Bevel Gears India Pvt Ltd (BGI), a specialist in high-precision gearing, has inaugurated a new 70,000 sq ft manufacturing facility near Kempegowda International Airport, Bengaluru, marking a major expansion of its aerospace manufacturing capabilities as the company celebrates 50 years of operations. The new facility is BGI’s first purpose-built aerospace manufacturing unit and forms a key part of its growth plans.
The company is targeting revenue of ₹500 crore by 2029 while continuing to serve customers across motorsport, mining, steel and industrial sectors in global markets. Designed specifically for flight-critical gearing, the facility brings together dedicated manufacturing, inspection and quality infrastructure to meet stringent requirements for dimensional accuracy, process control and product traceability.
“The facility has been designed around the requirements of flight-critical gearing, with dedicated manufacturing, inspection and quality infrastructure to support demanding tolerances, process control and complete traceability,” said Mushtaq Jamal, Director – Engineering & Business Development, Bevel Gears India.
The plant will manufacture spiral and straight bevel gears, zerol and angular bevels, beveloids, hypoid and high-ratio hypoid gears, curvic couplings and precision parallel-axis gearing. These products are intended for applications across aero-engines, helicopters, unmanned aerial vehicles, actuation systems and aerospace gearboxes, covering development programmes as well as serial production.
Located within Bengaluru’s expanding aerospace corridor, the facility gives BGI proximity to aerospace and aircraft OEMs, MRO companies, Tier-1 suppliers, and other industry participants. The investment comes amid increasing global sourcing from Indian aerospace manufacturers and the expansion of India’s precision engineering ecosystem.
“India’s aerospace sector is growing rapidly, with global engine and airframe makers expanding their supplier base in the country. Demand is also increasing for the complex, flight-critical gearing we have specialised in for five decades,” said Sulaiman Jamal, Managing Director, Jamal Group. “This plant allows us to take programmes from prototype and development quantities through to serial production across multiple platforms. We also offer reverse engineering services for legacy and obsolete parts, enabling customers to maintain their equipment.”
The facility includes Gleason and Klingelnberg CNC bevel and hypoid gear grinding lines, including a Gleason 275G CNC hypoid grinder with a special straight bevel grinding option and a Klingelnberg Oerlikon G80 CNC hypoid grinder. It is also equipped with DMG 5-axis machining centres and a climate-controlled metrology room featuring ZEISS coordinate measuring machines and Gleason gear inspection systems.
Gleason software and SolidWorks support gear design and tooth-contact analysis. A 10-tonne EOT crane provides material-handling support within the facility. BGI operates the new unit under AS9100D-certified aerospace quality systems and ISO 9001:2015 certification. Heat-treatment capabilities and NADCAP accreditation for special processes are planned for the next phase of development.
Founded in 1976 and part of the Jamal Group, Bevel Gears India is headquartered in Bengaluru and specialises in the manufacture of high-precision bevel gears. Its product range includes straight, spiral, zerol, angular and hypoid gears, covering sizes from a few millimetres to nearly two metres in diameter.
The company operates a high-mix, low-volume manufacturing model and serves customers in aerospace, space, motorsport, mining, steel and industrial markets worldwide. BGI was among the early Indian manufacturers to adopt CNC bevel gear grinding technology.
