Gleason showcases next-generation gear technology at IMTS

Gleason Corporation plans to exhibit its latest developments in gear design, manufacturing, and inspection technology, including closed-loop manufacturing and lights-out production at IMTS 2026, complemented by the Gleason Digital Ecosystem. Gleason’s gear technology experts will be available to discuss specific applications, such as the manufacture of gears for humanoid robots, aerospace and energy industries, as well as solutions addressing other key global trends shaping the future of gear manufacturing.

At IMTS 2026, Gleason Experts will be showcasing the technologies, processes, and manufacturing expertise that enable the production of the high-precision gears required for the rapidly growing humanoid robotics market. From typical humanoid robotic gear designs in KISSsoft and GEMS, like strain wave gears, planetary gearboxes and small bevel gears, new 80PS Power Skiving and Hobbing Machine and 100C Bevel Gear Cutting Machine, to address a large range of robotic gears, as well as the 175GMS nano for fine-pitch applications.

Gear design at system-level
KISSsoft Release 2026 offers the design and optimization of gears and transmissions, complemented by integrated system-level analysis. New features include flexibly configurable maps, support for REXS V1.7, new hob types, updated calculations for plastic gears and hydrodynamic plain bearings, as well as new modules for the design of hobbing and profile milling processes. Visitors can experience the new features firsthand and discuss trial licensing options directly with KISSsoft experts.

Profile grinding of external and internal cylindrical gears
The P600/800G Profile Grinding Machine provides exceptional versatility for the hard finishing of external and internal gears, worms and long shafts. Onboard gear inspection and innovative technology functions help improve quality and productivity while reducing manufacturing costs. The machine will be demonstrated live at IMTS 2026.

Metrology for surface finish, waviness and gear noise
With the 300GMSP nano Gear Metrology System for production environments, Gleason will demonstrate a metrology solution for measuring submicron surface finishes with skidless probe technology. Advanced software tools including Advanced Waviness Analysis and KTEPS analyze waviness in profile and lead and support the evaluation of gear noise behavior. With integrated cobot loading and the Gleason Closed Loop System, the solution becomes a key component of highly automated lights-out production strategies.

Closed-loop manufacturing for lights-out production
A major focus of the exhibit will be advanced Closed Loop Systems for highly automated production environments. Integrated solutions combine manufacturing, automation, gear inspection and digital process integration. Measurement data is transferred directly back to the manufacturing process, enabling manually prompted or automatic corrections. This helps increase productivity, process stability and gear quality with minimal operator intervention.

Double flank testing
Intra DFT Double Flank Testing Systems provide fast, reliable and production-ready gear quality verification. By simulating real operating conditions and capturing composite deviations in a single efficient test, the systems deliver immediate insight into gear performance and process stability. Intra Single Flank Testing systems are also available for applications requiring detailed transmission error analysis.

Criterion Analysis Software
Criterion Analysis Software provides the foundation for accurate and reliable gear inspection and analysis and is included with Intra Single and Double Flank Testing Systems. The software supports part verification, process monitoring and quality management, compares components with target specifications, monitors production using statistical process control and detects deviations early. Stored measurement data ensures complete traceability.

Functional and electronic gauges
Gleason will present a comprehensive portfolio of functional gauges, master gears, variable spline gauges, go/no-go rings and plugs, as well as setting and calibration masters. Experts will also discuss design engineering services, calibration options, coatings and setting masters, demonstrating how individual inspection requirements can be addressed efficiently.

Modular workholding
The QFS Quick Flex System provides flexible and cost-effective clamping for part families. The display will include advanced hydraulic and mechanical workholding systems for productive machining, LeCount expanding arbors for inspection applications, and customized solutions for special workpiece and process requirements.

Dressing tools
Grinding and honing applications often offer significant potential to improve quality, tool life and cost. Gleason dressing tools support higher productivity and consistently high results in hard finishing. Booth experts will discuss specific applications and individual optimization opportunities.

Power skiving tools
Gleason HSS and carbide power skiving tools combine high productivity with long tool life. They are available for all power skiving machines and machining centers with integrated power skiving capability and can be tailored to a wide range of gear manufacturing applications and production requirements.

Straight bevel and differential gears
The Coniflex Pro Design and Manufacturing System enables the cost-effective production of strong, quiet straight bevel gears. The technology is particularly well suited for high-performance differential applications in electric, internal combustion engine, and hybrid powertrains for passenger cars, trucks, buses, and off-highway vehicles.

Pitch hobs and milling cutters
Gleason offers a complete range of HSS and carbide hobs and milling cutters, from small to coarse pitch. The tools support automotive and industrial applications for cutting gears, splines, chain sprockets, pulleys and worm wheels. For the North American market, they are made in the USA by Gleason Cutting Tools.

Digital solutions for data-driven manufacturing
Gleason Digital Solutions (GDS) connects manufacturing processes in a data-driven ecosystem. Fingerprint Diagnostics supports proactive condition assessment, Process Monitoring supervises processes in real time, and Tool Management optimizes the use of production resources. The PMA Preventive Maintenance Assistant structures preventive maintenance activities. All applications are consolidated on the GEMS platform, creating the foundation for higher equipment availability, stable part quality, and AI-supported manufacturing strategies.

Precision plastic gears
Gleason Plastic Gears provides comprehensive solutions for high-precision plastic gears. Capabilities range from optimized gear tooth macro and micro geometry using KISSsoft, system analysis and design for moldability to custom material selection. Single- and multi-cavity molds, no weld-line technology, over-molding and additional manufacturing solutions support demanding applications.

For more information and to register for your free entry ticket, visit www.gleason.com/imts2026.