Reverse engineering is one of our core competencies. To reverse engineer worn gears, the process begins with a thorough visual and dimensional inspection of the received part—whether it is a worn gear, a broken sample, or simply the mating gear if the original is too damaged for direct measurement. We measure all physical dimensions, including outer diameter, root diameter, face width, bore size, and keyway geometry. For tooth geometry, we precisely measure pitch, pressure angle, helix angle (for helical gears), and tooth thickness at the pitch circle. For spiral bevel gears, we additionally measure spiral angle and mounting distance. All data is captured using either a coordinate measuring machine (CMM) with a rotary table or a dedicated gear measuring center such as Klingelnberg or Gleason. Based on these measurements, we reconstruct a full 3D solid model and perform tooth contact analysis (TCA) to verify geometry and contact pattern before any manufacturing begins. The entire reverse engineering phase typically takes 5 to 10 working days, depending on gear complexity and the condition of the received sample.