Gear transmissions that are quieter, lighter and proven by calculation.
GearLab is an independent engineering practice for gears and power transmissions. We rate and optimise gear sets, build NVH and multibody models that explain where noise comes from, design gearboxes from specification and train the engineers who will carry the work forward.
Calculations to ISO 6336, ISO 10300, AGMA 2001, DIN 743, VDI 2736.
- 2018
- founded by Dr. Davide Marano
- 100+
- consulting projects
- ~90
- companies trained since 2020
- 11
- training courses, on site or online
Six ways we work on your transmission
One engineer is responsible from the first data request to the final report. GearLab is independent of software resellers, so each recommendation follows the engineering problem, not a licence.
Gear and transmission calculation
Rating and optimisation of gears, shafts and bearings to international standards, with macro- and microgeometry tuned for strength, efficiency, mass and noise.
Service details: Gear and transmission calculationNVH and multibody simulation
From transmission error to radiated noise: flexible multibody models of gearboxes and e-drives that show where noise comes from and which change removes it.
Service details: NVH and multibody simulationGearbox design
Gearbox concepts and layouts for stationary and mobile machines, from a specification written with you to data ready for a prototype.
Service details: Gearbox designFailure analysis and reverse engineering
Root-cause analysis of damaged gears and gearboxes, and reconstruction of gear data for parts that have no usable drawing.
Service details: Failure analysis and reverse engineeringTesting and model correlation
With specialist test partners: modal analysis, vibration and noise measurements, and correlation of simulation models with what the hardware does.
Service details: Testing and model correlationDesign methods and validated models
Your own design method, written down: parametric models, design-of-experiments studies, validated safety factors and an internal handbook, so your team can repeat the result.
Service details: Design methods and validated models
Selected case studies
Recent projects, described without client names. Each one starts from a concrete question and ends with models, data and recommendations the customer keeps.
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NVH optimisation of an electromechanical brake-actuator gearbox
A validated multibody model shows where gearbox noise comes from; gear and housing changes reduce it and are checked against hardware.
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Main drive of a mechanical press: planetary or parallel?
Comparing two layouts for a high-torque eccentric press drive, then detailing the chosen one down to microgeometry.
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Integrally geared transmission for an ORC turbine
Pre-sizing a megawatt-class bull-gear transmission with three high-speed pinions at fixed centre distances.
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A design method for plastic gear transmissions
Turning plastic gear design from rules of thumb into a documented method, with safety factors validated against tests.
How a project runs
Work is split into short phases with a fixed price and delivery date. Every phase ends with a results meeting, so you can stop, adjust or continue with full information.
Scope
A first call and a data request: CAD, gear data, duty cycle, measurements you already have.
Offer
A written technical and economic offer, divided into phases with prices, deliverables and dates.
Model and analyse
Calculation, simulation and optimisation, with a review meeting at the end of each phase.
Deliver
Report, native calculation files and manufacturing data. Correlation with tests and team training on request.
The software licences needed for the work are included in the price. The applied standards are named in every report.
Training for gear engineers
Eleven courses on gear technology and on KISSsoft, KISSsys and RecurDyn, taught by Dr. Davide Marano at your site or online and adapted to your own models.
- Cylindrical gears: fundamentals2 days
- Cylindrical gears: NVH analysis and optimisation2 days
- Cylindrical gears: metrology and manufacturing errors1 day
- Bevel gears: fundamentals2 days
- Plastic gears: standards and design in KISSsoft2 days
- Worm gears: fundamentals1 day
- Splines: geometry, strength and modifications1 day
- Shafts and bearings: fundamentals2 days
Also from GearLab
Book
Cylindrical Gear Design
A practical guide to cylindrical gear design: ISO 6336 rating, microgeometry, transmission error and noise, shafts and bearings, and AI-driven optimisation, with KISSsoft examples.
Software, early access
GearLab AI Assist
Describe a calculation in plain language. GearLab AI Assist prepares the KISSsoft inputs for your approval, runs the sequence and assembles a report for review.
Visit gearlabai.com (opens in a new tab)Engineering built on research and on the shop floor.
GearLab was founded in 2018 by Dr. Davide Marano, after a PhD in industrial engineering and years of transmission engineering in the automotive industry. Today GearLab is a technical partner of KISSsoft and RecurDyn, publishes regularly at AGMA and VDI conferences and contributes to standards work.
About GearLabKISSsoft Technical partner since 2018
Consulting and training for gear, shaft and bearing calculation and for KISSsys system models.
RecurDyn Partner since 2020
Flexible multibody simulation of transmissions and mechanisms: kinematics, dynamics, vibration and noise.
Have a gear problem worth solving?
Describe the transmission and the question. Davide reads every message and replies personally.