Custom Electric Pickup Gears ProjectCase study / Electric vehicle components
Custom Electric Pickup Gears Project
An electric pickup project started with a 20-piece sample order. PairGears supported the machining, assembly discussions and delivery planning. The customer has since placed a bulk order.
- Application
- Electric pickup project
- Parts
- Custom gears and shafts
- Starting order
- 20-piece sample order
- Latest status
- Bulk order placed
What did PairGears do for this project?
PairGears supported an electric pickup gear and shaft project with a 20-piece sample order, assembly advice, quality review and split shipping. The customer has since placed a bulk order. The work included a customer-approved chamfer change and a remake plan for shaft samples with dimensional deviations.
Starting with the parts the customer needed to test
The customer needed custom gears and shafts for an electric pickup development project. The first order was for samples, so the immediate task was to support assembly and testing before a larger purchase.
Although the quantity was small, the parts still needed separate machining schedules, inspection requirements and delivery arrangements. PairGears tracked progress by part and shared updates on operations such as grinding and finish machining. That gave the customer a clearer view of the work still in progress.
For a buyer choosing a custom gear supplier, this early stage is also a chance to see how the supplier handles questions and changes. Our custom gear manufacturing service provides a starting point for discussing a drawing-based project.
| Customer need | PairGears support | Purpose for the buyer |
|---|---|---|
| Small sample quantity | Accepted the sample order and tracked each part's progress. | Start with parts for development and testing. |
| Press-fit assembly | Proposed a chamfer and agreed the change with the customer. | Improve the lead-in as the shaft enters the gear. |
| Quality review | Confirmed document support and cooperated with a third-party review. | Give the customer measurement information to assess. |
| Different delivery priorities | Planned air freight for urgent test parts and sea freight for the rest. | Balance test timing with freight cost. |
A small chamfer change to help with assembly
During the technical discussion, PairGears noticed that the original drawings did not call for a chamfer on certain gear edges. Those edges mattered during press fitting, when the shaft is pushed into the gear.
We suggested adding a lead-in chamfer to reduce the risk of catching or scratching the shaft during insertion. The team used marked locations and a simple illustration to explain the proposal, and offered to add the machining at no extra charge for this project. After the customer agreed, PairGears confirmed that the step would be added.
The change was modest, but it addressed a specific assembly concern. The customer could review the proposal before it became a manufacturing instruction.
Quality records, clear requirements and a remake plan
The customer requested quality information before shipment. PairGears confirmed support for material certificates, 100% inspection reports for specified critical dimensions, and hardness and metallographic reports. We also cooperated with a third-party on-site review arranged by the customer.
Project correspondence recorded initial acceptance of the dimensional measurements reviewed by the inspector. The agreed process called for quality documents to be submitted and the customer to confirm them before shipment.
What happened when some shaft dimensions were out of specification?
Some shaft samples had dimensional deviations. PairGears shared the measured values with the customer. When the customer confirmed that the parts could not be used, we agreed to scrap the nonconforming pieces and make replacements. The team then updated the remake schedule and adjusted the shipment quantities, with the replacements to follow separately.
The customer also raised a machining and hardness change. PairGears asked for the specific hardness target. Until a revised requirement was received, production followed the original drawing and hardness specification.
For your own project, agree which dimensions need inspection, which reports you need and how drawing changes will be approved. These details belong in the technical discussion before production.
Read about PairGears quality control for further information on our inspection approach.
Sending test parts first, with the rest by sea
The customer wanted test parts as soon as practical, while keeping freight costs under control for the rest of the order. PairGears worked with the customer on a split-shipment plan.
- Air freight
- Parts needed first for testing.
- Sea freight
- Remaining parts with a less urgent delivery requirement.
- Separate shipment
- Replacement parts after remanufacturing.
Separate invoices and packing lists showed the quantities, weights and package sizes for the shipments. PairGears also discussed freight options and the division of shipping costs with the customer. One part was set aside for transfer to the customer's nominated supplier in China to support related machining work.
When comparing freight quotations for a new order, confirm the delivery location and which charges each party will pay. The ICC's official explanation of Incoterms® rules is a useful reference for delivery responsibilities, costs and risk.
Project update
The customer has placed a bulk order
The relationship has moved beyond the initial 20-piece sample order. The customer has now placed a bulk order with PairGears.
During the sample work, the customer had direct experience of our production updates, assembly discussions, handling of nonconforming parts and shipping coordination. The follow-on order is the confirmed commercial outcome at this stage.
The next task is to carry the agreed requirements into the larger order, with continued attention to dimensional control, drawing revisions and production scheduling.
Questions buyers ask about custom EV gears
Can PairGears support a small sample order before bulk production?
PairGears accepted a 20-piece sample order in this electric pickup project. For a new project, send your drawings and required quantity so we can review the work. The quantity in this case is project-specific and does not set a standard minimum order for every part.
Which inspection documents should we discuss before ordering?
Discuss material certificates, inspection of critical dimensions, and any required hardness or metallographic reports. In this project, PairGears confirmed support for these documents and cooperated with a customer-arranged third-party review. Agree the scope and acceptance criteria for your parts before production.
Can you review assembly details on our gear drawings?
Send the relevant mating-part details with your drawings. In this case, PairGears proposed a lead-in chamfer for shaft assembly and obtained the customer's agreement before confirming the additional machining step.
Can urgent samples ship separately from the remaining parts?
Split shipping can be discussed against your schedule and destination. This project used a plan for urgent test parts by air, remaining parts by sea and replacement parts separately. The arrangement and freight charges need to be confirmed for each order.
More information for your sourcing review
Looking for a custom EV gear manufacturer?
Send your drawings and sample requirements to PairGears. We can discuss manufacturing feasibility, inspection requirements and a delivery plan for your project.
For a useful first discussion, include:
- Part drawings and the current revision
- Material, heat treatment and critical dimensions
- Sample quantity and expected bulk demand
- Inspection documents and acceptance criteria
- Required delivery date and destination
