As the gear industry enters a new phase of technological evolution, the future is no longer a distant concept; it’s taking shape in real time. The gears of change are in motion, driven by trends such as electrification, digitalisation, sustainability, and the evolving demands of end-user industries. Volume 3, Issue 4 of Gear Technology India explores this transformation through the lens of innovative research, process innovations, automation breakthroughs, and strategic insights, offering a detailed snapshot of where the gear industry is headed and how Indian manufacturers must prepare.
From frictional analysis at the micro level to cybersecurity at the macro scale, the technical articles in this issue converge on one idea: the gear industry is no longer operating in isolation, it is at the intersection of multiple fast-evolving domains.
In our Expert Column, we continue with Part 3 of an in-depth exploration into frictional forces at the tooth flanks of cylindrical gears. As gear systems are pushed to deliver greater performance under diverse load and lubrication conditions, understanding how friction behaves across the contact surface is no longer a theoretical pursuit, it is a design imperative.
This write-up draws attention to the way friction interacts with material properties, surface roughness, speed, and temperature, and how it can be managed to reduce power losses, improve wear resistance, and enhance overall efficiency. It lays the groundwork for practical applications, particularly in high-performance and precision-critical environments.
Another powerful transformation is taking place in surface engineering. In our Process feature, we dive into the revolutionary use of Diamond-Like Carbon (DLC) thin-film coatings for gears that must operate under extreme stress, temperature, and wear conditions. These ultra-hard, low-friction coatings are already proving their mettle in aerospace, motorsports, and next-gen automotive transmissions.
By reducing wear and friction, DLC coatings extend the service life of components and reduce the need for frequent lubrication, aligning well with sustainability goals. The article explores the various deposition techniques, performance benchmarks, and future possibilities of DLC in gear manufacturing—a vital development for gear makers seeking a competitive edge in premium applications.
As electric motors, especially BLDC (Brushless DC) motors—replace traditional powertrains across EVs, robotics, HVAC, and other industries, they bring with them new lubrication challenges. Our Lubrication feature takes a fresh look at how gear lubrication must evolve in this context.
Unlike internal combustion engine-driven systems, BLDC motors operate at higher RPMs and often in sealed or semi-sealed environments. This demands lubricants that resist oxidation, minimise drag, and operate effectively in compact, thermally dynamic settings. The article discusses innovative lubricant chemistries and application methods that gear designers must consider, especially when targeting the growing EV market.
While the gear industry has traditionally been rooted in mechanical precision, the integration of digital controls, IoT sensors, and cloud-based production monitoring systems has made cybersecurity a critical concern. In our Tech Innovation section, we examine how gear manufacturers, especially in India, can no longer treat digital security as an afterthought.
From protecting intellectual property (IP) and machine codes to ensuring uptime across interconnected networks, the article outlines practical steps for building cyber-resilient factories. As Indian gear producers grow into global supply chain partners, they will increasingly be judged on how well they safeguard data, automation assets, and customer privacy.
The future of transportation in India is electric, and so is the future of its gearing systems. Our Automation article unfolds the evolution of high-tech gearing for electric vehicles, especially in the context of compactness, noise reduction, and torque optimisation.
Unlike traditional internal combustion engines, EVs generate near-instant torque and operate more quietly. This places new demands on gear systems: they must be lighter, stronger, and quieter. Automated manufacturing and inspection systems are making this possible by ensuring micron-level consistency, faster prototyping, and higher reliability. India’s EV suppliers must now catch up to global expectations—or risk being left behind.
In Product News, we bring readers the latest innovation from Sunnen, which introduces its HTA all-electric tube hone. With increasing pressure to reduce energy consumption and improve repeatability, this solution offers enhanced control, flexibility, and efficiency, attributes that are especially valuable in precision gear applications.
Sunnen’s technology highlights a broader trend toward electrification in manufacturing systems, not just in products. This signals a shift toward more intelligent, sustainable production solutions that fit into a smarter, greener industrial landscape.
In this issue’s Tech News, we report on Gleason Corporation’s acquisition of the Intra Group of Companies, a move that signals deeper integration between global leaders and specialised regional players. The acquisition strengthens Gleason’s presence in India and enhances its ability to offer end-to-end gear production solutions. This deal is emblematic of the larger industry trend: multinational players are recognising India not just as a market, but as a manufacturing hub and innovation partner.
What can the gear industry learn from the semiconductor sector? In our Industry Outlook feature, we draw compelling parallels between these two seemingly dissimilar domains. Both rely on tight tolerances, massive capital investments, and globalised supply chains. The article urges Indian gear makers to adopt the semiconductor mindset: embrace automation, invest in R&D, and standardise quality benchmarks to scale globally.
Is the gear industry a niche market or a foundational one? This article feature tackles this philosophical, and strategic question head-on. Gears are everywhere: in vehicles, wind turbines, medical devices, robotics, aerospace systems, and factory automation. Yet the sector often struggles for recognition and investment.
The article argues for a rebranding of the industry’s image, one that communicates its centrality in the modern industrial economy and attracts the next generation of engineers, designers, and entrepreneurs.
In another Industry Outlook piece, we explore how changing needs from the automotive, aerospace, defence, and renewable energy sectors are reshaping the future of gear manufacturing. Customers today demand lighter components, lower noise, higher power density, and faster delivery cycles.
This has led to major changes in material science, surface finishing, additive manufacturing, and mechatronic integration. Gear makers that align closely with end-user needs, not just at the procurement level but at the design and co-development stage, will be the ones to thrive in this new landscape.
On the Inspection front, we present PRED-D: a novel approach to predictive diagnostics based on first-principles physics. Unlike traditional machine learning models that rely on historical data alone, PRED-D systems interpret real-time data through the lens of mechanical laws, offering deeper, context-aware insights into system health.
This approach marks a shift from reactive or even predictive maintenance toward diagnostic intelligence, where machines understand the “why” behind anomalies, not just the “when.”
Finally, our Press Release section summarises the groundbreaking technologies showcased at EMO, where global players presented tools and services aimed at transforming the gear industry. From hybrid machining centres to advanced cutting tools and AI-powered inspection solutions, the exhibition aspires to prove that modernisation is no longer optional, it’s the basis for survival.
The message across all these articles is clear: the Indian gear industry must shift gears. How? The answer is; strategically, technologically, and structurally. Whether it’s through deeper research in tribology, smarter automation, global strategic partnerships, or reimagining lubrication and inspection, the time to act is now.
With the global manufacturing sector evolving at an unprecedented pace, gear makers are uniquely positioned to drive progress rather than simply adapt to it. This edition of Gear Technology India goes beyond insights, it serves as a roadmap to help navigate and shape the industry’s future.
Welcome to the future of gears. It’s smarter, faster, and more connected than ever before.
