Large gear manufacturing at IGW: our biggest gear yet

At IGW, large gear manufacturing is not a marketing claim. It is a practical capability, proven on the shopfloor. We machine gearwheels up to Ø 2.3 m as part of our industrial gear offering, supporting customers who need high torque, reliable performance and controlled geometry at scale.

Recently, we reached a new internal milestone: the largest gear ever produced within IGW, with a diameter of Ø 2.2 m. Before this project, we had already delivered Ø 2.0 m gears. This time, the extra 200 mm mattered. Not only for machining and inspection, but also for something more basic and just as critical: moving the part safely through the building.

Why a Ø 2.2 m gear changes the process

When gear diameter increases, standard assumptions quickly stop being reliable.

A few extra centimetres can affect the machine envelope, clamping strategy, tool approach, inspection setup and internal logistics. Cranes, turning devices, transport routes, floor load, turning radius and door clearance all become part of the manufacturing plan.

Large gear manufacturing is rarely only a machining challenge. It is a complete process challenge: planning, execution, verification and handling. Each step needs the same discipline as the cutting operation itself.

At IGW, that end-to-end mindset is part of how we work. By keeping key steps in-house, we maintain control over the process, reduce uncertainty and support predictable outcomes.

The measuring stick that protected the schedule

For this project, our team introduced a simple but effective tool: a dedicated measuring stick representing the critical outer dimensions of the gear and its handling setup.

Why a physical measuring stick?

Because in real production environments, the tightest constraint is not always the machine. It can be the route between stations. The turning area, crane travel corridor, staging zones and doorways can all become critical.

The measuring stick helped us validate early and repeatedly that:

• the gear would fit the machining setup as planned
• the gear could be moved safely between operations
• the gear could pass through every doorway and bottleneck
• no last-minute rework, disassembly or unnecessary risk would be introduced

The result was fewer surprises, clearer internal communication and a smoother path toward first-time-right execution.

What customers gain from proven large gear capability

When sourcing a gear of this size, customers need predictable delivery and verified performance. The goal is not heroic problem-solving near the deadline. The goal is a controlled process from the start.

IGW supports large gear projects with:

• controlled geometry and verification for demanding industrial requirements
• in-house process control across key manufacturing steps
• the ability to manufacture large gearwheels up to Ø 2.3 m
• practical expertise in handling, inspection and integration
• a global manufacturing footprint to support customers worldwide

For machinery where uptime matters, these details translate into fewer delays, fewer deviations and more confidence during commissioning.

Let’s talk about your large gear project

If you are considering a gear in the Ø 2.0 to Ø 2.3 m range, or if you are not sure what is feasible within your assembly constraints, IGW can support you from feasibility through delivery.

Our team combines large gear manufacturing expertise with practical input on handling, inspection and integration.

Learn more about our gear capabilities on our website.
Reach out to our team: sales@igwpower.com