Sintered Gears
SINTERED GEARS
Sintered Gears Manufactured in Massachusetts
Atlantic Sintered – Precision Powder Metallurgy for High-Performance Gear Applications Worldwide
Massachusetts-Made. Globally Delivered.
At Atlantic Sintered, we engineer and manufacture precision sintered gears for customers around the world. Proudly based in Massachusetts, USA, we are one of North America’s most experienced and trusted names in Powder Metallurgy (PM)—offering over 40 years of innovation, consistency, and precision in gear manufacturing.
Our gears are used in vehicles, industrial automation, power tools, robotics, and agricultural equipment on every continent. With proprietary technologies like our HD4 Process™ and Gear Tooth Surface Densification, we provide components that meet or exceed forged gear performance—while offering global manufacturers the cost, weight, and design flexibility advantages of sintered metal.
Whether you’re in Boston or Berlin, Tokyo or Toronto, Atlantic Sintered delivers engineered solutions with speed, quality, and precision.
Why Choose Sintered Gears?
Sintered gears, produced through powder metallurgy, combine performance and efficiency for high-volume, high-performance applications. Unlike traditional machined or forged gears, PM gears are manufactured close to final shape, reducing material waste and production time.
Key Advantages of Powder Metallurgy Gears:
- Near-net-shape forming – Minimal machining required
- Excellent dimensional repeatability – Ideal for mass production
- Efficient material use – Reduced scrap and optimized cost
- Design flexibility – Enables complex shapes, undercuts, and integrated features
- Self-lubricating options – Useful in maintenance-sensitive applications
- Scalable manufacturing – Supports both prototyping and millions of parts
At Atlantic Sintered, our sintered gear technology is trusted not only in Massachusetts—but also by OEMs and Tier 1 suppliers across global markets in automotive, robotics, medical devices, and fluid power systems.
The HD4 Process™: Advancing Powder Metallurgy
Our proprietary HD4 Process™ is a breakthrough in sintered gear manufacturing, enabling us to achieve high density, high-strength components capable of competing with forged alternatives.
What Makes HD4™ Different?
- Densities up to 7.4 g/cm³ for superior core strength
- Improved torque resistance and fatigue durability
- Tight porosity control for dynamic mechanical performance
- Ideal for high-load automotive, industrial, and EV drivetrain applications
The HD4 Process™ unlocks a new level of material performance—giving global manufacturers the power to reduce costs, minimize weight, and simplify machining without sacrificing strength.
Surface Densification: Forged-Like Strength, Powdered Metal Efficiency
Traditional sintered gears can suffer from surface porosity, which limits contact fatigue resistance. At Atlantic Sintered, we overcome this with Gear Tooth Surface Densification—a technology that transforms the surface of each gear tooth to achieve forged-like density, hardness, and finish.
Benefits of Gear Tooth Surface Densification:
- Rolling contact fatigue strength equal to forged gears
- Mirror-like surface finish to reduce NVH and wear
- Custom tooth profile crowning for optimized load distribution
- Eliminates secondary operations like hobbing or grinding
- Retains cost and production advantages of PM
This process allows us to serve high-demand applications such as electric vehicle drivetrains, robotics, and heavy machinery with confidence—delivering performance and consistency globally.
Massachusetts-Based Manufacturing. World-Class Capabilities.
Our fully integrated facility in Massachusetts includes every step of the powdered metal gear manufacturing process—from material mixing to final quality inspection. This allows us to maintain tight control over quality, lead times, and production scalability for our global clients.
Our In-House Capabilities Include:
- Advanced compaction and sintering equipment
- CNC and robotic densification systems
- In-house tooling design and maintenance
- Full metrology lab with CMMs, gear analyzers, and metallographic testing
- Scalable production for prototypes to multi-million-unit programs
Because we own the process end-to-end, we can react faster, ship quicker, and meet international standards across a wide range of industries.
Applications for Sintered Gears Around the World
From startups in Massachusetts to OEMs in Germany and industrial groups in Japan, our sintered gears power precision systems across the globe.
Key Application Areas:
1. Automotive and Electric Powertrains
Lightweight, noise-reducing, and fatigue-resistant gears for hybrid systems, timing assemblies, and EV transmissions.
2. Electric Motors and Gearboxes
Precision PM gears for small motors, stepper drives, planetary systems, and servo units in automation equipment.
3. Industrial Machinery and Robotics
Reliable gear performance in actuators, conveyors, and motion-control systems, where dimensional accuracy is mission-critical.
4. Agricultural and Construction Equipment
High-load sintered gears for rugged field environments, providing corrosion resistance and low maintenance.
5. Consumer Products and Medical Devices
Compact, quiet-operating gears for tools, appliances, pumps, and motor-driven surgical systems.
Wherever reliability, repeatability, and efficiency matter—Atlantic Sintered gears deliver.
Quality Assurance from Design to Delivery
We maintain rigorous standards to ensure every sintered gear meets global performance requirements. Quality is embedded in every phase of the process—from initial design to shipping.
Our QA Lab Includes:
- Coordinate Measuring Machines (CMMs)
- Gear profile and pitch analyzers
- Hardness and porosity testers
- Statistical process control (SPC) tools
- Full traceability and inspection reports
We collaborate with your engineering team to ensure our sintered gears meet your application’s specific load, lifecycle, and tolerance requirements. We also offer Design for Manufacturability (DFM) reviews, rapid prototyping, and materials guidance.
Supporting Massachusetts—and the World
While we’re deeply rooted in Massachusetts' industrial legacy, our customer base is international. We serve:
- Global automotive OEMs
- Tier 1 and Tier 2 suppliers
- Medical device manufacturers
- Robotics startups and integrators
- Industrial equipment leaders
Why Global Clients Choose Us:
- U.S.-based production with international shipping expertise
- Local support with global reach
- Fluent in international quality and compliance standards
- Export-ready logistics and documentation support
- Proven performance across borders and industries
Whether you’re designing in Detroit or assembling in Seoul, we deliver gear solutions you can trust.
Let’s Build a Better Gear—Together
If you’re sourcing sintered gears for critical applications or exploring Powder Metallurgy to reduce cost, weight, or complexity, Atlantic Sintered is ready to help. From rapid prototyping to high-volume global fulfillment, we support your project every step of the way.
Atlantic Sintered – Gear Solutions Forged from Innovation. Engineered for the World.