Total Solution. Optimal Performance. Competitive Edge.
As experts in the field of custom injection molded gearing, Thermotech offers a full range of services. From Design through Tooling, Molding, Inspection and Assembly - our total solution provides you with the techniques, tools and expertise you need to optimize the performance and cost-effectiveness of your plastic gear transmissions.

"Introduction to Direct Gear Design^®" - Paper presented by Thermotech at the Global Powertrain Congress 2005, September 2005. Direct Gear DesignŽ is a Trademark of AKGears.

"Direct Gear Design for Automotive Applications" - Paper presented by Thermotech at the SAE 2005 World Congress, April 2005. Direct Gear DesignŽ is a Trademark of AKGears.

"Direct Gear Design Drives Performance" - Article published in Gear Solutions, January 2004. *
* Article has been modified slightly for use on Thermotech's website. Direct Gear DesignŽ is a Trademark of AKGears.

Direct Gear Design^®
The process of developing a high performance gear train begins with effective design. Plastic gears have traditionally been engineered using standards developed for machined metal gears. This method is indirect because it is based on the parameters of the cutting tool. Direct Gear DesignŽ is a Trademark of AKGears.

At Thermotech, we employ the Direct Gear Design methodology. With direct design, the gear parameters are defined first, based on the precise operating conditions and desired performance of the gear train. Maximizing performance and cost effectiveness are the primary objectives. The tool is defined by the gear geometry, not vice versa. The end result is a gear transmission that functions precisely to the customer's performance priorities. Direct Gear DesignŽ is a Trademark of AKGears.

Click here to view a side-by-side comparison of the gears designed by the traditional method and those designed by Direct Gear Design. Direct Gear DesignŽ is a Trademark of AKGears.

Direct Gear Design results in improved performance. Direct Gear DesignŽ is a Trademark of AKGears:

Increased Load Capacity Size & Weight Reduction Noise & Vibration Reduction Increased Reliability Cost Reduction Increased Efficiency Longer Life

Measurement / Inspection
At Thermotech, we employ two kinds of gear inspection, functional and analytical.

Functional Inspection is provided by the double flank roll tester. We employ top-of-the line equipment for measuring accuracy and repeatability of results. The roll tester is integrated with gear measurement software, which quickly compares the actual gear geometry with the customer's original design specification. The software also collects and analyzes gear inspection data for ongoing statistical process control.

Analytical Inspection at Thermotech involves state-of-the art CMM scanning. The scanning probe precisely measures each individual tooth, creating a digital topographical image of the complete gear. The CMM integrates with a Direct CAD Interface, comparing the scan data with the CAD model. The gear specific module of the software calculates elemental gear accuracy parameters, such as runout, profile, pitch, and lead errors.

Tooling
Precision tooling is essential to successful molding, and in this arena Thermotech is amongst the industry's leading innovators.

One of the unique development tools that Thermotech uses is Genetic Molding Solution^SM, a computer-modeling algorithm applied for one-step tool cavity correction. It analyzes three data sets (the gear design profile, the 1st tool cavity profile and the profile of the molded sample) to precisely calculate the final cavity profile. The use of this technology results in shorter product qualification and faster time to market.

Assembly
Thermotech provides complete contract manufacturing services. With our efficient manual assembly operation in Mexico and our expertise in automation, we can develop the most cost effective assembly option to meet the needs of any program.