Global Telecom Equipment Supplier × Honscn Precision: Flat-Profile Gear Innovation Drives Cost Reduction and Market Expansion

Project Overview: From Standard Gears to Cost-Saving Innovation

(a) Initial Product Requirements

This project primarily targets the galvanized iron gears (material: S235JR)  used in digital television antenna rotators . Key specifications include:

• Diameter: 38mm, 16 teeth (module 1.5)

• Surface treatment: 8-12μm yellow zinc plating (ASTM B633 Type II), with corrosion resistance.

• Tooth profile tolerance: ±0.05mm, ensuring smooth rotation.

(II) Our Value-Added Design Scheme

While manufacturing according to the customer's drawings, our engineering team discovered an opportunity: the hollow center (12 mm in diameter) at one end of the gear lacked a positioning device, requiring secondary machining to achieve assembly alignment. We proposed a modified solution with a flat profile —adding a 4 mm wide flat section to the hollow end—which offers two key advantages:

• Secondary operations are eliminated : the flat profile can be directly aligned during assembly, thus reducing two processing steps.

• Faster production process : Simplified clamping of CNC lathes reduces cycle time by 18 seconds per unit.

Challenge: Balancing plating quality and dimensional stability

(a) Control of galvanized thickness

The zinc plating on iron components often leads to dimensional deviations, but gear tooth pitch requires tight tolerances. Our solution:

• A allowance of -0.03mm is left during pre-plating processing to compensate for plating buildup.

• Post-plating inspection was performed using a Keyence 3D scanner to verify tooth profile accuracy (up to ±0.02 mm).

(ii) Planar machining accuracy

The new planar portion needs to be perpendicular to the tooth surface within 0.02 mm to ensure proper alignment. We solved this problem in the following way:

• Gear teeth and planar contours are machined in one operation using a 4-axis CNC lathe equipped with powered cutting tools.

• Laser measurements are used during the implementation process to correct for changes in material hardness (S235JR tensile strength: 370-500MPa).

Manufacturing Process: A Combination of Efficiency and Precision

(I) Production Workflow

• Material preparation : Cold-drawn S235JR round bar (40 mm in diameter), cut into 50 mm lengths, deburred to remove sharp edges.

• CNC turning : A 4-axis lathe machined the outer diameter, hollow center, and planar contour in one cycle (cycle time: 45 seconds, compared to the original design of 63 seconds).

• Gear hobbing machine : YK3120 gear hobbing machine can process 16 teeth with a precision of DIN8 grade.

• Surface treatment : galvanized wire, pickling (to remove oxides) and trivalent chromium passivation (to achieve 72 hours of salt spray resistance according to ASTM B117).

Quality Inspection : 100% inspection of tooth pitch, planar profile dimensions, and plating thickness is conducted using the Mitutoyo Quick Vision measuring system.

(ii) Cost-saving mechanism

Results: Expanding the market through superior engineering technology

(a) Customer impact

• Cost reduction : Unit production costs are reduced by 19%, enabling customers to operate at 12% lower costs than competitors.

• Market growth : Three new contracts were secured, including one with a major U.S. telecommunications provider, due to enhanced price competitiveness.

• Efficiency Improvement : Output increased by 25% with the same equipment, meeting peak demand in the fourth quarter.

(ii) Customer Feedback

Honscn's flat profile innovation revolutionized our gear assembly—we not only reduced costs but also improved assembly reliability. Their ability to turn standard parts into a competitive advantage is why we're extending our partnership to five other components.

—Marco Schmidt, Director of Customer Engineering

Industry Value: Reimagined Telecom Components

This case study showcases Hongsen Precision's expertise in optimizing telecommunications equipment , combining manufacturing precision with cost-effective design. Our approach—integrating materials science (galvanization control), CNC machining efficiency, and value-added engineering—delivers components that drive customer growth in a highly competitive market.

Ready to optimize your telecom components?

Whether you need to reduce costs, improve design, or scale up production, our team can help you transform standard components into strategic assets. Contact us  to discuss how to enhance the performance of your telecom equipment components.