Reverse engineering is a common request. The process starts with receiving your worn or broken gear — or the mating gear if the worn one is too damaged. We measure all physical dimensions: outer diameter, root diameter, face width, bore size, and keyway. For tooth geometry, we measure pitch, pressure angle, helix angle (for helical gears), and tooth thickness. For spiral bevel gears, we also measure spiral angle and mounting distance. We then create a 3D model and tooth contact analysis to verify geometry before manufacturing. We always recommend replacing the gear as a matched pair (pinion and gear) for bevel gears to ensure proper contact pattern. Reverse engineering typically takes 5-10 working days, depending on gear complexity.