Sand Casting, Metal Forging & CNC Machining for Industrial Gearboxes
When an agricultural equipment manufacturer needed a reliable replacement for an existing right-angle gearbox, they turned to The Federal Group USA to reproduce the complete assembly while maintaining the original dimensions, fit, and performance.
The project required several different manufacturing processes to produce the gearbox components, including sand casting, metal forging, and CNC machining.
The Challenge: Replacing a Legacy Industrial Gearbox
The customer’s existing gearbox manufacturer was no longer able to produce a right-angle gearbox used in agricultural equipment. Replacing it with a standard design would have required modifications to the customer’s existing machinery, creating additional costs, engineering work, and potential downtime.
The customer needed two gearbox configurations—clockwise and counterclockwise—that would maintain the original mounting dimensions, interfaces, and performance characteristics. The replacement components also needed to work with the customer’s existing equipment without significant modifications.
Developing a Manufacturing Solution
TFG evaluated samples of the existing gearboxes and used dimensional measurements and 3D scanning to establish the geometry and critical dimensions of the components. This information was used to develop CAD models and manufacturing drawings that could be used for production.
With the design requirements established, TFG selected the appropriate manufacturing process for each component based on its geometry, strength requirements, and dimensional tolerances. The project combined sand casting, metal forging, and CNC machining to produce the major gearbox components.
Sand Casting for the Gearbox Housing
TFG leveraged its experience sand casting components for agricultural equipment to produce the gearbox housing’s complex geometry and meet the strength requirements of the application. The cast housing was manufactured to the required dimensions and incorporated the mounting features and interfaces needed for installation.
An industrial corrosion-inhibiting coating was then applied, and the customer’s logo was incorporated into the housing. Sand casting provided an efficient solution for producing the durable housing required for the agricultural equipment application.
Metal Forging for the Gear Components
The gearbox gears required strength and durability to withstand the loads associated with power transmission. TFG manufactured the gear blanks using metal forging before machining them to their required dimensions.
Forging provided a strong starting point for the gear components, while subsequent machining brought the gears to the dimensional requirements necessary for proper operation within the gearbox assembly.
CNC Machining for Precision Components
The gearbox included shafts with several critical machined features. TFG used CNC machining to produce retaining ring grooves, sealing surfaces, threads, bearing-fit surfaces, and other precision features required on the shafts.
CNC machining provided the dimensional accuracy and repeatability needed for these components to interface properly with the gears, bearings, seals, and other gearbox components.
Complete Gearbox Assembly and Testing
In addition to manufacturing the primary components, TFG facilitated the procurement of required buyout components, including fasteners, bearings, seals, and snap rings. The individual components were then assembled into complete gearboxes.
Each component and completed assembly underwent testing to verify dimensional and performance requirements. Once testing was complete, the customer inspected the finished gearboxes for proper operation and excessive noise.
The completed gearboxes were installed onto the customer’s original agricultural equipment and interfaced successfully without requiring significant modifications.
The Result: A Reliable Replacement Manufacturing Solution
By combining sand casting, metal forging, and CNC machining, TFG was able to manufacture the major components required for a complete replacement gearbox while maintaining the original design requirements.
The customer avoided the time and expense associated with modifying existing equipment to accommodate a different gearbox design. The completed assemblies provided a direct replacement solution while giving the customer a manufacturing partner capable of supporting future gearbox components and replacement parts.
Looking for a Manufacturing Partner for Custom Agriculture Components?
Whether you need gearbox housings, gears, shafts, brackets, hubs, pulleys, hydraulic components, or other custom agricultural machinery parts, TFG USA can help identify the right manufacturing solution for your application.
Client Testimonials
Trustindex verifies that the original source of the review is Google.
David Detuccio2026-08-11The Federal Group has demonstrated professionalism, responsiveness, and a willingness to collaborate during the initial stages of our relationship. Communication has been timely, and they have shown a commitment to understanding our requirements and business expectations. Responsive communication and follow-up. Competitive pricing and commercial flexibility. Good product/service quality during initial orders. Cooperative approach to resolving issues and answering questions. Demonstrated interest in building a long-term partnership. Alanna and Sandor are amazing!Trustindex verifies that the original source of the review is Google.Judd Stretcher2026-08-11Great communication and quality parts at a fair price. They really make sure your happy with your parts.Trustindex verifies that the original source of the review is Google.Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.
