Bevel Gears India Opens Dedicated Bengaluru Facility for Aerospace and Defence Gearing

Bevel Gears India has opened a new 70,000-square-foot manufacturing facility near Kempegowda International Airport in Bengaluru, expanding its capacity to produce precision gearing for aircraft engines, helicopters, unmanned aerial vehicles and other aerospace systems.

The facility, located in Bengaluru’s aerospace and defence manufacturing corridor, is the company’s first plant built specifically for aerospace applications. It was inaugurated on August 31 as Bevel Gears India marked 50 years since the establishment of its engineering business in 1976. Detailed information on the facility was released on September 8.

The plant has been designed around the tighter manufacturing tolerances, process controls, inspection requirements and component traceability required for flight-critical parts.

It will manufacture spiral and straight bevel gears, zerol and angular bevel gears, beveloids, hypoid and high-ratio hypoid gears, curvic couplings and precision parallel-axis gearing. These components can be used in aero-engines, helicopter transmissions, UAV systems, actuators and specialised aerospace gearboxes.

Gearing is a relatively small part of an aircraft by physical size, but it performs some of the most demanding mechanical tasks. Aero-engine accessory gearboxes, helicopter transmission systems and actuators must transmit power reliably while operating under high rotational loads, vibration and changing temperatures. Manufacturing these parts requires very precise control over tooth geometry, surface finish and alignment.

Bevel Gears India has installed specialised equipment for that work at the new plant.

The facility includes Gleason and Klingelnberg CNC bevel and hypoid gear-grinding systems. The company says the equipment includes India’s first Gleason 275G CNC hypoid grinder with a straight-bevel grinding option and the country’s first Klingelnberg Oerlikon G80 CNC hypoid grinder.

DMG five-axis machining centres provide additional manufacturing capability, while inspection is carried out in a climate-controlled metrology facility equipped with ZEISS coordinate measuring machines and Gleason gear-inspection systems. Gear design and tooth-contact analysis are supported by specialised Gleason software and SolidWorks.

The combination is intended to allow the company to handle a component from initial engineering and prototype production through qualification and serial manufacture.

Sulaiman Jamal, Managing Director of the Jamal Group, said the new facility would allow Bevel Gears India to support programmes from prototype and development quantities through to series production across multiple aerospace platforms.

The company also plans to offer reverse-engineering services for legacy and obsolete aerospace components. This can be particularly relevant to maintenance organisations operating older aircraft for which the original component manufacturer no longer supplies a particular gear or replacement part.

In such cases, an existing component can be measured and its geometry recreated before a replacement is manufactured and subjected to the required inspection and qualification procedures.

Building More of the Aerospace Supply Chain in India

The plant comes as Indian manufacturers seek a larger role in global aerospace supply chains.

Aircraft and engine manufacturers rely on extensive networks of specialist suppliers for components such as gears, forgings, castings, actuators, bearings and machined structures. Companies that can consistently meet aerospace tolerances and documentation standards can participate in programmes well beyond India’s domestic aircraft market.

Bevel Gears India already exports its products and specialises in custom, high-mix and relatively low-volume gear manufacturing. Its existing capabilities include gear design, reverse engineering, cutting, lapping, grinding and inspection to DIN and AGMA standards.

The new plant gives that business a dedicated aerospace production environment rather than relying solely on facilities serving a broader industrial customer base.

Its location is also useful. Bengaluru and the surrounding region contain HAL facilities, aerospace suppliers, maintenance companies and a growing number of private-sector aviation and defence manufacturers. Being located near that ecosystem reduces the distance between a specialist component supplier and many of its potential customers.

Aerospace Qualification Is the Next Step

The facility operates under AS9100D-certified aerospace quality systems and also holds ISO 9001:2015 certification.

Bevel Gears India plans to add its own heat-treatment capability in the next phase and obtain NADCAP accreditation for special processes.

That is a significant part of the expansion.

Producing the shape of an aerospace gear is only part of the manufacturing process. Heat treatment is used to achieve the hardness, fatigue resistance and wear characteristics required for components expected to operate for long periods under substantial loads.

NADCAP accreditation is widely used by the global aerospace industry to qualify suppliers carrying out specialised manufacturing processes. Securing it would improve the company’s ability to undertake work for international aerospace OEMs and Tier-1 suppliers that require approved special-process sources.

The company is targeting revenue of ₹500 crore by 2029 as it expands the aerospace business while continuing to serve customers in motorsport, mining, steel and other industrial sectors.

For Bevel Gears India, the new Bengaluru facility represents a move from supplying precision gears across several industries to establishing a dedicated production base for aerospace-grade components.

Its commercial progress will ultimately depend on qualification with aircraft, engine and systems manufacturers and on converting development work into long-term production programmes. The plant gives the company the machinery, metrology and quality infrastructure needed to compete for that work.

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