DMG MORI is kicking off the second half of 2026 with practical solutions for integrated gear machining. The gearMILL software, along with the gearBROACHING, gearSHAPING, gearHOBBING, and gearSKIVING technology cycles, enable selected gear-cutting operations on appropriately equipped machining centers, turn-mill centers, and 5-axis machines. The dialog-guided software solutions assist users in programming and executing various gear-cutting processes, thereby making it easier to get started with cost-effective gear cutting without special-purpose machines. This allows job shops and medium-sized contract manufacturers in particular to tap into new opportunities without having to outsource gear-cutting orders to external specialty firms. This reduces internal coordination efforts, shortens lead times, cuts costs, and ensures faster delivery times. However, the benefits go beyond just the added value. The possibilities for turnkey machining are also expanding: turning, milling, gear cutting, and measurement can be integrated even more seamlessly into a continuous process chain. Furthermore, turnkey machining can open the door to standard automation and pave the way for higher machine utilisation rates.
DMG MORI gearMILL: Compatibility with standard tools as well
DMG MORI gearMILL is not a technology cycle in the strict sense, but rather software for producing complex gear geometries that makes it very easy to implement custom profile and flank modifications. This also makes it easy to adapt load patterns and meet customer-specific requirements. The integrated CAM module then ensures efficient programming using standard tools. The achievable gear quality here is ≥ 5 according to DIN/ISO, which meets the requirements for prototypes, replacement parts, and small production runs in many industries.
Technology Cycles for Recurring Gear Cutting Tasks
As soon as specific gear geometries are produced on a regular basis, it’s worth making the switch to process-specific cycles. gearSKIVING 2.0 (hobbing) is up to eight times faster than conventional hobbing and enables the production of internal and external gears up to module 11 with a quality grade of ≥ 7. On turn-mill centers in the NTX and CTX TC series, this also applies to helical gears with tooth offset. gearHOBBING covers the hobbing of spur and helical spur gears. gearBROACHING is designed for position-oriented broaching of internal and
external gear teeth up to module 4. And gearSHAPING supports the production of internal or external gear teeth using gear shaping. All cycles can be retrofitted as a pure software solution—on both new and existing machines.
Integrated Measurement: 40 Percent Fewer Process Steps
A key factor in boosting productivity is optical measurement of gear teeth using a laser scanner directly during the machining process. With 70,000 scan points per second and more than 80 percent of the measurement points within ±2 µm, the solution achieves the accuracy of an external coordinate measuring machine. Compared to the conventional process, which involves separate measurement and re-clamping steps, the number of process steps is reduced from ten to six, and the total process time is cut by more than 50 percent. Machining and measurement take place in a single clamping operation. Correction values are thus fed back immediately, which offers quality and logistical advantages, particularly for larger components.
Complete machining in a single setup
Turning, milling, gear cutting, and measuring can all be performed on DMG MORI turn-mill centers in a single setup. The CTX TC and NTX series also enable complete 6-side machining without manual re-clamping. This, in turn, creates optimal conditions for the cost-effective use of standard automation solutions such as the Robo2Go. Even small and medium-sized service providers can thus benefit from shorter lead times, less in-house transport, and a predictable production flow without sacrificing flexibility in their day-to-day operations.
Modular Roadmap for Small and Medium-Sized Businesses
DMG MORI positions universal gear cutting as a practical first step toward Machining Transformation (MX) especially for small and medium-sized CNC shops looking to expand their range of services in a targeted manner using their existing machines. A two-step approach is recommended: In the first step, DMG MORI gearMILL opens up new business opportunities for users in the areas of prototypes, replacement parts, and small production runs, without requiring specialised gear-cutting machines or special tools. In the second step, process-specific cycles, automation solutions, and digitisation modules can be added as soon as gear cutting tasks become a regular part of operations or medium-sized batch sizes need to be produced cost-effectively. All DMG MORI technology cycles can be retrofitted as software solutions, making them accessible for existing machines with minimal investment.
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