{"id":1971,"date":"2026-10-08T07:32:06","date_gmt":"2026-10-08T07:32:06","guid":{"rendered":"https:\/\/metalite.net\/?p=1971"},"modified":"2026-10-08T07:44:55","modified_gmt":"2026-10-08T07:44:55","slug":"non-standard-worm-gearbox","status":"publish","type":"post","link":"https:\/\/metalite.net\/en_ca\/application\/non-standard-worm-gearbox\/","title":{"rendered":"Non-Standard Worm Gearbox: Custom Ratios, Shafts & Materials"},"content":{"rendered":"
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Every industrial worm gearbox in EPG Canada’s standard range was designed to fit the majority of applications. The majority is not all applications. When a machine’s spatial envelope won’t accept a standard center distance, when the required gear ratio falls between two catalog options, when the output shaft configuration is proprietary, or when the operating environment demands material specifications that no catalog unit carries \u2014 the non-standard worm gearbox program is the correct path forward.<\/p>\n

This page explains when a non-standard worm gearbox is the right decision, what can be engineered to meet your requirements, the design parameters needed to generate a technical proposal, and how to structure an enquiry so EPG Canada can respond with a preliminary specification and pricing within 48 hours. For application scenarios that commonly require custom gearboxes, see our Non-Standard Worm Gearbox Applications guide<\/a>.<\/p>\n

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When Should You Specify a Non-Standard Worm Gearbox?<\/h2>\n
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\"Non-standard<\/p>\n

Custom worm gearboxes engineered to specific dimensional envelopes, ratios, materials, and output configurations<\/p>\n<\/div>\n

The decision to specify a non-standard gearbox is driven by one of five conditions \u2014 when any of these applies to your application, attempting to force-fit a catalog unit will either compromise the machine design or result in premature gearbox failure:<\/p>\n

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1. Dimensional Constraint<\/p>\n

The machine’s spatial envelope requires a center distance, housing footprint, or shaft position that no standard unit provides. This is the most common trigger for a non-standard specification \u2014 particularly on retrofits replacing obsolete gearboxes whose dimensions were never standardised.<\/p>\n<\/div>\n

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2. Non-Standard Ratio<\/p>\n

The required output speed falls between catalog ratio steps \u2014 for example, a process requiring exactly 23 RPM from a 1,450 RPM motor needs a 63:1 ratio, which is not a standard catalog step. Specifying the nearest standard ratio (60:1 \u2192 24.2 RPM, or 80:1 \u2192 18.1 RPM) produces a process speed outside tolerance.<\/p>\n<\/div>\n

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3. Shaft Configuration<\/p>\n

The application needs a shaft diameter, keyway, flange bolt circle, or spline that differs from standard catalog output shafts. Common on machinery where the gearbox interfaces with a proprietary driven component \u2014 pump impellers, agitator arms, custom tooling spindles.<\/p>\n<\/div>\n

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4. Material Requirement<\/p>\n

The operating environment requires housing or gear material that catalog units don’t supply: stainless steel housing for salt spray or aggressive chemical exposure, food-grade certified housing material, special alloy worm shaft for high-temperature service, or upgraded sealing for submerged installation.<\/p>\n<\/div>\n

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5. Performance Above Catalog Rating<\/p>\n

The application’s torque, speed, or load profile exceeds what catalog units at the required ratio and frame size can deliver, and stepping up to the next frame size creates dimensional conflicts. A custom gear pair at optimised tooth geometry can increase torque capacity at the same center distance.<\/p>\n<\/div>\n<\/div>\n

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What Can Be Customised? Full Scope of Non-Standard Options<\/h2>\n
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Category<\/th>\nStandard Options<\/th>\nNon-Standard Options Available<\/th>\n<\/tr>\n<\/thead>\n
Gear Ratio<\/td>\n5, 7.5, 10, 15, 20, 25, 30, 40, 50, 60, 80, 100:1<\/td>\nAny ratio from 3:1 to 120:1 in a single stage; custom multi-stage for higher ratios<\/td>\n<\/tr>\n
Center Distance<\/td>\n25, 30, 40, 50, 63, 75, 90, 110, 130, 150 mm (RV\/Aluminum) or 40\u2013250 mm (WP)<\/td>\nAny center distance within the feasible gear pair range \u2014 to match retrofit dimensional requirements<\/td>\n<\/tr>\n
Output Shaft<\/td>\nStandard solid shaft with metric keyway; hollow bore (standard sizes)<\/td>\nAny diameter; inch or metric; inch keyway; spline; threaded end; custom flange; shrink disc; integrated pinion<\/td>\n<\/tr>\n
Input Shaft<\/td>\nHollow input for motor coupling; solid projecting shaft (WPS)<\/td>\nCustom input shaft for non-standard motor interface; hydraulic motor mount; PTO input; handwheel input<\/td>\n<\/tr>\n
Housing Material<\/td>\nAluminum alloy (small frames); cast iron (large frames)<\/td>\nStainless steel 304\/316; ductile iron; fabricated steel; special alloy<\/td>\n<\/tr>\n
Worm Shaft Material<\/td>\n45# carbon steel or 20CrMnTi alloy, carburized<\/td>\nStainless steel 17-4PH; H13 tool steel for high-temperature; nitrided 42CrMo for extended wear life<\/td>\n<\/tr>\n
Worm Wheel Material<\/td>\nTin bronze (Cu-Sn-10-3); aluminum bronze<\/td>\nPhosphor bronze (higher strength); leaded bronze (improved machinability for odd pitches); engineering polymer (non-metallic, low-noise)<\/td>\n<\/tr>\n
Sealing & IP Rating<\/td>\nIP54 standard; IP65 with Viton seals<\/td>\nIP67 \/ IP68 submersible; ATEX (explosion-proof) rated housing; H1 food-grade lubricant and seals<\/td>\n<\/tr>\n
Mounting Configuration<\/td>\nFoot, flange, hollow bore, torque arm<\/td>\nIntegrated base plate; custom bolt pattern; multi-axis mounting; integrated motor bracket for non-standard motor frame<\/td>\n<\/tr>\n
Worm Thread Starts<\/td>\nSingle-start (standard for high ratio)<\/td>\nMulti-start worm (2, 3, or 4 start) for higher efficiency at equivalent ratio; dual-lead worm for controlled backlash adjustment<\/td>\n<\/tr>\n
Surface Treatment<\/td>\nStandard epoxy primer + PU topcoat (RAL 5010)<\/td>\nHot-dip galvanizing; electroless nickel plating; anodizing (aluminum); powder coat; epoxy-phenolic for chemical resistance<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

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Design Parameters Required for a Technical Proposal<\/h2>\n

The completeness of the specification provided determines the accuracy and speed of the technical proposal. A complete specification generates a preliminary proposal within 48 hours; an incomplete one requires a clarification round that delays the schedule. The following parameters are required \u2014 provide as many as possible in your initial enquiry:<\/p>\n

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MANDATORY \u2014 Proposal Cannot Be Generated Without These<\/p>\n<\/div>\n

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