About Custom Sheaves

What you should know.

Sheave Industry’s Fastest Lead Times- 2 to 4 Weeks!

Process Sheaves LLC has developed over 300 custom design sheaves to meet critical customer parametersMany applications, particularly in wire & cable processing, have design constraints that can’t be met by stock sheaves from us or other suppliers. In recent years, Process Sheaves LLC has developed over 300 custom design sheaves to meet critical customer parameters. We welcome the opportunity to work with you to achieve the most economical solution for your particular situation.

Lead Times
Custom sheaves expressly designed to meet you exact requirements can usually be shipped within 2 to 4 weeks after receipt of your order. Quotations are usually delivered within 24 to 48 hours after receipt of your inquiry.

Design Process
The custom sheave design process is relatively simple. You tell us which are the constraining parameters – OD, bending radius, weight, temperature, shaft diameter, etc – and we will propose solutions. Refer to our order form under the ‘Request Quotation’ link. We must have maximum product size and minimum bending radius (Root Diameter).

It is generally uneconomical to purchase fewer than ten identical sheaves due to engineering and setup costs.

The simplest sheaves (and most sheaves) require three distinct CNC operations and each step requires programming and setup time.
Materials are purchased to requirements. Very small orders for one or two pieces are relatively expensive.

For less than ten sheaves, it may be more economical to modify a stock sheave.

Prices for thirty or more identical sheaves will often be comparable to stock sheaves of a similar size.

For custom sheaves of 22” OD or less, we prefer Gar-Dur, the densest and most abrasion resistant UHMW-PE available commercially. It is available in a variety of sizes and shape from stock, generally yellow in color. This material was originally developed for mallet faces that must stand up to continuous pounding blows. We have been using it for 15 years and have experienced excellent results.

Other materials we use are:
Other UHMW-PE, especially for sheaves over 22” OD.
HDPE for lower performance and lower cost.

For less than ten sheaves, it may be more economical to modify a stock sheave.

Cast polyamide, for special applications.
D2 Tool Steel

Composites such as carbon fiber are our newest development in sheave manufacturing. We have a technical collaboration with a leading aerospace manufacturer that promises to yield lightweight, strong, sheaves with excellent wear characteristics. We have seen weight savings of 50% with no compromise in expected performance.

Due to tooling costs, these sheaves are economical only if the ultimate requirements will be 100 or more. However, sheaves of 30″ OD and larger may be very cost competitive even in smaller quantities. As our experience grows, we will post some case studies on our web site to give you concrete examples or weight and cost advantages.

Our products can be statically or dynamically balanced to suit your requirements. Normally balancing is not required because precision machining of homogeneous materials produces inherently balanced finished sheaves, requiring no dynamic balancing for 1500 RPM and above.

Contact us with your sheave requirements before freezing your equipment designs. We can offer a better sheave at a lower cost in many cases, if we are consulting early in the design stage. Many times a modification of our standard sheaves is the economical choice when certain design parameters preclude use of an off-the-shelf sheave. Even fully custom sheaves can be quite economical when the right decisions are made on materials and designs. Put our experience to use for your business.