Micron-level tolerances at IGW: maintaining precision even on large components

​At IGW, precision is measured in microns. We strive for micron-level tolerances through every step of production. On one project, our team achieved a tolerance of 15 microns on a gear with a diameter of around 2 metres.

What does a micron-level tolerance mean?

A micron is one thousandth of a millimetre. So 15 microns equals 0.015 mm. To make that more understandable, 15 microns is in the range of a thin sheet of kitchen aluminium foil. It is also much thinner than a human hair.

Why 15 microns is difficult on a 2-metre gear

A micron-level tolerance with a large steel component depends on temperatures too.

Steel expands when temperature changes. As a practical rule of thumb, steel expands by roughly 12 microns per metre per degree Celsius. On a 2-metre gear, a temperature change of just 1°C can already create around 24 microns of dimensional change.

That is more than the 15-micron tolerance itself. This is why precision gear manufacturing depends on more than machine capability. Temperature, clamping, tool behaviour, machine stability and measurement conditions all influence the final result.

Precision is measured throughout the process

For tolerances like this, measurement is not something that only happens at the end.

Critical features are checked during the process, so the team can verify whether machining remains stable and within the required limits. Final inspection is still essential, but it confirms the result of a controlled process. A 15-micron tolerance on a 2-metre gear is only possible when machining and metrology work together from the start.

What micron-level gear tolerances mean for customers

For customers, tolerances are not just numbers on a drawing. They determine how a gear fits, runs and performs inside demanding rotating equipment. When geometry is controlled at micron level, it supports accurate assembly, stable operation and reliable performance over time.

At IGW, achieving micron-level tolerances is the result of stable machining, controlled conditions and experienced people who understand how small deviations can affect large components. That is where precision becomes repeatable.

That is why micron-level tolerances have to be built into the process.

​Talk to us about precision manufacturing

Do you have a project where tight tolerances, stable machining and reliable measurement are critical?

We machine gears with a diameter of up to 2,3 meters. Our team can support you from feasibility to production, with practical input on geometry, process control and manufacturability.

Contact our sales team via sales@igwpower.com or get in touch through our contact page.