Gear Metrology Moves to the Center of Closed-Loop Manufacturing
Gear manufacturing is increasingly moving toward a model in which inspection is no longer a downstream quality-control activity, but an integral part of the production process. At IMTS 2026, Gleason will demonstrate how advanced gear metrology, functional testing and digital manufacturing technologies are supporting this transition.
Gleason will showcase solutions covering gear design, manufacturing, inspection and digital process integration, with particular emphasis on closed-loop manufacturing and lights-out production.
Production-Speed Gear Metrology
A key metrology highlight will be the 300GMSP nano Gear Metrology System, designed for production environments requiring high-resolution measurement alongside automated operation.
The system uses skidless probe technology to measure submicron surface finishes, while Advanced Waviness Analysis and KTEPS software evaluate profile and lead waviness and support analysis of gear noise behaviour.
Integrated cobot loading and connection to the Gleason Closed Loop System enable measurement results to become part of an automated production feedback loop.
From Measurement to Correction
Closed-loop manufacturing will be a central theme at the exhibit. Measurement data can be transferred directly back to the manufacturing process, allowing manually prompted or automatic corrections.
Rather than simply identifying nonconforming components, this approach allows manufacturers to monitor process trends and correct deviations before they result in significant scrap or quality problems.
This capability is particularly important for lights-out production, where inspection must provide actionable information without requiring continuous operator intervention.
Functional Gear Testing
Gleason will also demonstrate Intra DFT Double Flank Testing Systems, providing rapid production verification of composite gear deviations. Intra Single Flank Testing systems are available for applications requiring detailed transmission-error analysis.
Complementing these systems, CRITERION Analysis Software provides part verification, statistical process monitoring, quality management and measurement-data traceability.
Together, analytical measurement and functional testing provide manufacturers with a broader understanding of gear quality—from dimensional accuracy and waviness to the functional behaviour of a gear pair.
Metrology for Next-Generation Gears
Humanoid robotics is one of the emerging applications driving demand for increasingly precise, compact gears. Gleason will showcase manufacturing technologies for strain wave gears, planetary gearboxes and small bevel gears, including the 80PS Power Skiving and Hobbing Machine, 100C Bevel Gear Cutting Machine and 175GMS nano for fine-pitch applications.
As gear dimensions and tolerances become increasingly demanding, high-resolution measurement and process control become essential to achieving repeatable transmission performance.
Integrating Inspection with Manufacturing
The P600/800G Profile Grinding Machine will demonstrate how inspection can be incorporated into the gear finishing process. Designed for external and internal cylindrical gears, worms and long shafts, the machine includes onboard gear inspection and technology functions intended to improve quality and productivity.
Gleason will also present functional gauges, master gears, spline gauges and other inspection equipment, highlighting the continued importance of combining advanced analytical metrology with fast production-oriented verification.
The Digital Metrology Connection
Gleason Digital Solutions extend the measurement and manufacturing workflow into a broader data ecosystem. Applications including Fingerprint Diagnostics, Process Monitoring, Tool Management and preventive maintenance are consolidated through the GEMS platform.
By connecting measurement data with machine condition, tooling and process information, manufacturers can move toward predictive quality control rather than simply reacting to defective parts.
Measurement Becomes Manufacturing Intelligence
Gleason’s IMTS 2026 portfolio demonstrates the changing role of gear metrology. Measurement is increasingly becoming an active component of manufacturing, providing the feedback required to maintain process stability, reduce variation and support autonomous production.
From gear design and cutting through grinding, inspection and functional testing, the emerging model is a continuous loop of manufacture, measure, analyse and correct—providing the foundation for higher-quality and increasingly lights-out gear production.
For more information: www.gleason.com
