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For Dontyne Gears, the combination of their pioneering software and the Okuma GENOS M460V-5AX machining centre supplied by NCMT has transformed what’s possible. Through this partnership, Dontyne Gears has not only demonstrated the viability of manufacturing some of the most complex gear geometries on a standard 5-axis platform. It has redefined how precision gear production can be achieved efficiently and accurately.
Dontyne Gears sought a different path, to create intelligent software that could generate the code and cutting strategy directly from the gear design software to manufacture precision gears on a standard, multi-purpose machining centre using readily available tooling. To make that vision a reality, they needed a platform capable of extraordinary accuracy and adaptability. That platform was the Okuma GENOS M460V-5AX.
“The Okuma GENOS M460V-5AX gave Dontyne the flexibility and precision they needed to validate their groundbreaking software,” said Andrew Skee, Sales Manager, Northeast England and Scotland at NCMT.
From concept to capability
For Dr. Michael Fish, Director of Dontyne Systems, the investment was a key shift in technology. Despite challenges, vigorous testing and reprogramming helped develop a software module enabling gear projects.
“Having the Okuma machine allowed us to prove our software on real parts,” said Dr Fish. “We can now take a gear pair design checked for correct contact and simulate the machining cycle with given tool selection and machine type. Once confirmed, it can generate code in seconds for complex tooth forms, export a file to cut the gear, and measure it within our own cell. We fitted a SPRINT system from Renishaw plc to the GENOS to measure cylindrical gears, which has been transformative. It has enabled us to show customers what’s achievable, we often produce ISO 4-5 results on the first attempt.”
Dontyne’s software creates complex tooth geometries that enhance performance and durability, including micro geometries measured in microns. Working with the machine’s probing and measurement systems, the team verifies precision on the machine, reducing setup time and eliminating costly specialist tooling.
Intuitive platform
Dontyne’s integration of digital design and manufacturing reflects Industry 4.0 principles. The Gear Production Suite (GPS) from Dontyne Systems creates a virtual twin for gears, automatically generating G-Code for exact tooth form and sending digital files to inspection machines. The GENOS, equipped with Renishaw’s SPRINT probe, inspects external and internal gears where geometry allows. “Dontyne’s work showcases exactly what’s possible when you combine advanced software with a truly capable machine tool,” said Andrew Skee.
Redefining The Standard
Dontyne’s software has demonstrated the ability to cut a wide range of gear types. This includes spiral bevels, hypoids, helicals, internal gears and non-regulation special-profile forms. Traditionally, these forms would require a dedicated machine.
By enabling all of these geometries to be cut on one flexible machine with a unified software environment, Dontyne has challenged long-standing assumptions in the gear industry, and what once took months can now be done in days. Further, tooling for traditional production can be expensive, costing thousands, and can add weeks to lead times for each design.
As Fish explains: “We’ve shown that with the right software and the right machine, you can produce these parts with incredible precision. Manufacturers now have a viable, flexible alternative to traditional production that will significantly reduce gear production cost and time. Stepping up to a Multus would enable a complete part to be produced on one machine”
Industry Recognition
It is not just manufacturers who are standing up and taking notice of these technological advances in gear production. The British Gear Association (BGA) has played a crucial role in raising awareness across the industry by funding a study of Dontyne’s method. Recognising the exceptional results achieved by Dontyne and the potential of current flexible machine tools for the industry, the BGA provided further support to investigate the production of other gear geometries. Throughout the development process, the BGA committee has served as both a challenger and a validator.
Dr Fish said: “By challenging claims, validating results and supporting further adaptations, the BGA is helping us establish further credibility around this approach to gear manufacture through peer review of projects relating to 5-axis CNC production. Their backing not only enabled technical progress but has also given industry recognition that our methods address long-standing limitations in gear-making.”
By combining their software with Okuma’s 5-axis technology and NCMT’s support, Dontyne Gears has not only advanced their own capabilities but opened new doors for the entire industry. It’s proof that the right partnership can turn vision into reality and that with the Okuma GENOS M460V-5AX, even the most complex engineering challenges like gear manufacturing can be met head-on.
