Custom Gear with Shaft Bore – Configure Round Bore, D-Shaft, Keyway, Square or Hex Bore Online

Configure a Custom Gear with the Right Shaft Connection

A gear only performs reliably when it fits the shaft correctly. While standard gears usually come with a simple round bore, many applications require a more secure torque transmission. Our online gear configurator lets you combine the correct gear geometry with the shaft connection your project needs. Configure the number of teeth, module, face width and shaft bore in just a few clicks, then download the STL file or order a professional 3D print.

Which Shaft Bore Should You Choose?

Round Bore

A standard round bore is ideal when the gear is secured using set screws, clamping hubs or a press fit. It is the most common solution for general mechanical applications.

D-Shaft Bore

A D-shaped bore includes one flat side that matches a D-shaft. This prevents slipping and provides reliable torque transmission without requiring additional machining. D-shaft gears are commonly used in electric motors, robotics, household appliances and automation equipment.

Keyway Bore

For higher torque applications, a keyway is often the preferred solution. The key transmits torque directly between the shaft and the gear, making it suitable for industrial machinery, conveyors and heavy-duty mechanical systems.

Square Bore

A square bore creates a positive mechanical connection on square shafts. It is frequently used for positioning mechanisms, adjustment systems and custom engineering projects.

Hex Bore

A hexagonal bore is ideal for hex shafts and applications requiring high torque transfer while still allowing quick assembly and disassembly.

Additional Gear Parameters

Besides the shaft connection, the configurator allows you to define the number of teeth, gear module, face width, shaft size and optional hub dimensions. This makes it possible to create a gear that fits both the transmission requirements and the mechanical shaft interface.

Typical Applications

• Replacement gears for machines
• Electric motor gears
• Robotics and automation
• DIY engineering projects
• Industrial machinery
• Prototype development
• Custom 3D printed gears

Why Use a Parametric Gear Configurator?

Finding a standard gear with the correct number of teeth, module and shaft connection is often difficult. A parametric gear configurator allows you to combine all required dimensions in a single model without CAD software. This reduces design time and helps you produce functional replacement parts quickly.

Download the STL or Order a 3D Print

Once your configuration is complete, you can immediately download the STL file for your own 3D printer or order a professionally manufactured gear directly through our service.

Frequently Asked Questions

Which shaft bore is best for electric motors?

D-shaft bores are among the most common choices for small electric motors.

When should I use a keyway?

A keyway is recommended whenever higher torque transmission is required between the shaft and the gear.

Can I configure a square bore?

Yes. The configurator supports square shaft bores with customizable dimensions.

Does the configurator support hex bores?

Yes. Internal hex bores are available for compatible shaft applications.

Configure Your Custom Gear Now

Select the number of teeth, module, face width and the ideal shaft connection for your application. Generate a custom gear in minutes and download the STL file or order a professional 3D print.