DMG MORI has introduced a new range of integrated gear machining solutions designed to help small and medium-sized CNC manufacturers expand their capabilities without investing in dedicated gear-cutting machines. The company’s latest software and technology cycles allow users to perform gear machining on compatible machining centres, turn-mill centres and 5-axis machines, enabling manufacturers to complete more operations in-house while reducing production costs and delivery times.
The new offering includes DMG MORI gearMILL software along with the gearBROACHING, gearSHAPING, gearHOBBING and gearSKIVING technology cycles. These solutions simplify programming and execution of different gear-cutting processes through user-friendly, dialog-based software, making advanced gear production accessible even for companies with limited experience in gear manufacturing.
By bringing gear machining into existing production facilities, manufacturers can reduce dependence on external suppliers, shorten lead times and improve overall production efficiency. The integrated process also allows turning, milling, gear cutting and inspection to be completed within a single workflow, improving productivity while maintaining high quality standards.
The DMG MORI gearMILL software supports the production of complex gear profiles using standard cutting tools. It allows users to create customised gear geometries and make profile adjustments to meet specific customer requirements. The integrated CAM module simplifies programming and enables manufacturers to achieve gear quality suitable for prototypes, replacement parts and small production batches across multiple industries.
For businesses handling recurring gear production, DMG MORI offers specialised technology cycles that improve machining speed and efficiency. The gearSKIVING 2.0 cycle significantly increases production speed while supporting both internal and external gears. The gearHOBBING cycle is designed for spur and helical gears, while gearBROACHING enables accurate machining of internal and external gear teeth. The gearSHAPING cycle provides another option for producing precision gear profiles. All these software-based solutions can be installed on both new and existing compatible machines.
A key feature of the system is its integrated laser-based gear measurement capability. The solution performs high-speed optical scanning directly inside the machine, eliminating the need to move components to external measuring equipment. This reduces production stages, shortens machining time by more than half and allows immediate process corrections, improving both quality and productivity.
DMG MORI’s turn-mill centres further support complete machining in a single setup, allowing turning, milling, gear cutting and measurement without manual re-clamping. The system is also compatible with automation solutions such as Robo2Go, enabling manufacturers to increase machine utilisation while maintaining flexibility for smaller production runs.
With these integrated technologies, DMG MORI aims to help CNC manufacturers diversify their services, improve operational efficiency and enter new markets with minimal additional investment. The company believes its scalable software-based approach provides an effective pathway for manufacturers seeking to expand into gear machining while making better use of their existing equipment.
