Bevel Gears India Pvt Ltd (BGI), a Bengaluru-based manufacturer of high-precision gearing, has inaugurated a new 70,000 sq ft manufacturing facility near Kempegowda International Airport, strengthening its capabilities to serve the aerospace sector and marking a significant milestone as the company completes 50 years of operations.
The new plant is BGI’s first purpose-built aerospace manufacturing facility and has been designed specifically to support the production of flight-critical gearing. The company is targeting revenues of ₹500 crore by 2029 as it expands its aerospace business while continuing to serve customers in motorsport, mining, steel and other industrial markets globally.
Built for flight-critical applications
The facility brings manufacturing, inspection and quality functions under one roof, with infrastructure designed to meet the stringent dimensional accuracy, process control and traceability requirements associated with aerospace components.
“The facility has been designed around the requirements of flight-critical gearing, with dedicated manufacturing, inspection and quality infrastructure to support demanding tolerances, process control and complete traceability,” said Mushtaq Jamal, Director – Engineering & Business Development, Bevel Gears India.
BGI will manufacture a broad range of precision gearing at the facility, including spiral and straight bevel gears, zerol and angular bevels, beveloids, hypoid and high-ratio hypoid gears, curvic couplings and precision parallel-axis gearing.
These components are intended for applications across aero-engines, helicopters, unmanned aerial vehicles (UAVs), actuation systems and aerospace gearboxes. The facility is expected to support both development programmes and serial production, allowing BGI to participate across different stages of an aerospace programme.
Strengthening India’s aerospace supply chain
The plant’s location within Bengaluru’s growing aerospace corridor is strategically significant. It places BGI close to aircraft and engine OEMs, MRO providers, Tier-1 suppliers and other aerospace companies, potentially improving collaboration on development programmes while shortening supply-chain links for precision components.
The investment comes as aerospace manufacturers in India increasingly seek to develop local supplier ecosystems and as global aerospace companies expand sourcing from the country.
“India’s aerospace sector is growing rapidly, with global engine and airframe makers expanding their supplier base in the country. Demand is also increasing for the complex, flight-critical gearing we have specialised in for five decades,” said Sulaiman Jamal, Managing Director, Jamal Group. He added that the facility is designed to take programmes from prototype and development quantities through to serial production across multiple platforms.
For the aftermarket, BGI’s reverse-engineering capability could also be significant, particularly for operators and MRO organisations supporting older aircraft and aerospace platforms where original components may be obsolete or difficult to source.
“We also offer reverse engineering services for legacy and obsolete parts, enabling customers to maintain their equipment,” Jamal said.
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High-Precision manufacturing infrastructure
The new facility is equipped with advanced gear manufacturing and inspection technologies, including Gleason and Klingelnberg CNC bevel and hypoid gear grinding systems.
Key equipment includes a Gleason 275G CNC hypoid grinder with a special straight bevel grinding option and a Klingelnberg Oerlikon G80 CNC hypoid grinder. The facility also incorporates DMG five-axis machining centres for complex precision machining requirements.
Quality assurance and dimensional inspection are supported by a climate-controlled metrology room equipped with ZEISS coordinate measuring machines and Gleason gear inspection systems. Gleason software and SolidWorks are used for gear design and tooth-contact analysis. A 10-tonne EOT crane has also been installed to support material handling within the manufacturing facility.
Aerospace quality and future capabilities
BGI is operating the new facility under AS9100D-certified aerospace quality systems, alongside ISO 9001:2015 certification. The company plans to further expand the facility’s capabilities, with heat-treatment processes and NADCAP accreditation for special processes planned as part of the next phase of development.
The addition of these capabilities would allow BGI to progressively bring more specialised processes into its aerospace manufacturing ecosystem, potentially reducing external dependencies and supporting tighter control over component quality and production lead times.
MRO opportunities
For the MRO sector, the expansion is particularly relevant because precision gearing is a critical element across several aerospace systems, including engines, helicopter transmissions, actuation systems and gearboxes.
As aircraft fleets age, the availability of replacement components, repair support and engineering solutions becomes increasingly important. BGI’s combination of new-component manufacturing and reverse engineering could therefore provide an additional route for supporting legacy platforms and hard-to-source gearing. At the same time, its ability to move from prototype quantities to serial production positions the company to support new aerospace programmes as they mature.
Founded in 1976, BGI is part of the Jamal Group and operates a high-mix, low-volume manufacturing model. Its product portfolio spans straight, spiral, zerol, angular and hypoid gears, ranging from components measuring a few millimetres to nearly two metres in diameter.
The company was also among the early Indian manufacturers to adopt CNC bevel gear grinding technology.
With the new aerospace facility, BGI is now seeking to build on that manufacturing experience and establish a larger role in India’s evolving aerospace supply chain. For the MRO sector, the development points to a broader trend: the growing availability of specialised Indian manufacturing capabilities that can support both next-generation aerospace programmes and the continued operation of legacy platforms.
