Precision Contract Broaching Services for Every Application
Trusted by leading manufacturers across North America, our contract broaching services in Menomonee Falls, Wisconsin deliver keyway, spline, and blind-hole broaching to ANSI and ISO tolerances — from single prototypes to high-volume production runs, backed by in-house tool design and inspection.
Contract Broaching Services
At Broaching Technologies, we deliver precision internal machining for customers who demand exact tolerances and consistent quality. Our contract broaching services combine advanced equipment, decades of engineering expertise, and custom tooling design to handle everything from single prototypes to large production runs.
Outsource Precision. Gain Consistency and Confidence.
Broaching is one of the most efficient methods for producing internal forms like keyways, involute splines, and blind-hole geometries — but not every facility has the equipment, tooling, or expertise to run it in-house. Compared to alternatives like milling, gear shaping, or wire EDM, broaching delivers higher throughput and tighter dimensional control on repeated internal features. Partnering with Broaching Technologies gives manufacturers access to vertical and horizontal broaching machines, hydraulic broaching presses, and CAMS slotting machines — plus decades of broaching experience — without the capital investment or learning curve.
Why Choose Contract Broaching
Key Benefits
- Tight-tolerance machining for keyways, splines, and custom forms
- Lower tooling and setup costs compared to in-house broaching
- High repeatability for production volumes or prototype work
- Shorter lead times through optimized setups and quick changeovers
- Custom tooling design and reconditioning handled in-house
Comprehensive In-House Broaching Expertise
Our facility is equipped to handle a wide range of broaching operations — from through-hole keyways to blind-hole splines requiring specialized tooling geometry and chip relief. We operate both vertical and horizontal broaching systems to achieve exceptional precision and finish quality.
Keyway Broaching
Internal keyways for gears, pulleys, sprockets, and shaft couplings, cut to ANSI B17.1 parallel key and ISO 3117 Woodruff key standards. Our keyseater and pull-broach setups produce square, rectangular, and Woodruff keyseats with smooth torque transmission and accurate hub alignment.
Spline Broaching
Internal and external spline forms — including involute splines to ANSI B92.1 and straight-sided splines to DIN 5480/5482 — for shafts, hubs, drive assemblies, and power transmission components. We hold pitch diameter, major diameter, and side-fit tolerances for perfect concentricity and mating fit.
Blind-Hole Broaching
Advanced internal machining for blind keyways and blind splines where the broach cannot exit through the workpiece. This requires specialized push-broach tooling with modified chip relief geometry and shortened cutting length — a specialty few shops can perform accurately. Common on gearbox housings, valve bodies, hydraulic manifolds, and actuator components.
In-House Tooling, Engineering, and Process Control
We collaborate with customer engineers to evaluate part geometry, material, and tolerance requirements before production begins. Whether the project involves high-volume automotive parts or custom aerospace components, every detail is dialed in for performance and consistency.
- Custom broach design, CAD/CAM support, and DFM (design for manufacturability) review
- Broach sharpening, regrinding, reconditioning, and repair — HSS M2, M42, and PM (powder metallurgy) tool steel broaches
- Process optimization for specific alloys and geometries, including case-hardened and pre-hardened steels
- CMM inspection, GD&T verification, surface finish (Ra) measurement, and first article inspection (FAI) to your tolerance grade (IT6–IT8)
Precision Across a Range of Materials and Industries
Our broaching services support a wide variety of metals and alloys, delivering precise results in even the most demanding materials.
Materials
- Carbon and alloy steels, tool steels (D2, A2, H13)
- Stainless steel (304, 316L, 17-4 PH), duplex stainless
- Aluminum (6061, 7075) and brass
- Titanium, Inconel, Hastelloy, Monel
- Cast iron (ductile and gray), sintered powdered metals, phosphor bronze
Applications
- Spur, helical, bevel, and planetary gears; sprockets
- Pulleys, hubs, and shaft couplings
- Valve, pump, and hydraulic manifold components
- Transmission, differential, and drive shaft assemblies
- Aerospace, defense, automotive, agricultural equipment, wind energy, and medical device components
How Our Contract Broaching Services Work
From initial consultation to finished parts, our process is designed for precision, communication, and turnaround speed.
Consultation & Review
Discuss your part design, tolerances, and production goals.
Tooling & Setup
Custom broach and fixture design tailored to your requirements.
Machining & Inspection
Broaching performed with precision, followed by detailed quality verification.
Delivery & Support
Parts delivered on schedule with optional re-broaching or tool maintenance services.
Ready to Simplify Your Precision Machining Workflow?
Whether you need a single prototype or high-volume production, Broaching Technologies provides turnkey contract broaching backed by decades of hands-on expertise and CAMS slotting technology.
Frequently Asked Questions
What industries benefit most from contract broaching services?
Can I request custom broaching services for prototype parts?
How do precision broaching services improve part consistency?
What are the typical lead times for contract broaching services?
Do you provide support with part and tool design for custom broaching services?
Are blind hole features compatible with precision broaching services?
How do I get started with a quote for contract broaching services?
What is contract broaching?
Contract broaching is a subcontract manufacturing service where a specialized shop performs broaching operations — cutting internal keyways, splines, or custom forms — on parts supplied by another manufacturer. It lets OEMs outsource work that requires dedicated broaching machines, custom tooling, and technical expertise without the capital investment.
Broaching vs. milling — when should I choose broaching?
Broaching is faster and more accurate than milling for producing internal forms like keyways and splines, especially at production volumes. Milling remains better for one-off parts or when the internal features must be varied. For repeated internal geometries with tight tolerances, broaching delivers superior throughput and consistency.
What tolerances can broaching achieve?
Precision broaching routinely holds IT7 tolerances on internal forms and can achieve surface finishes below 32 µin Ra. Actual results depend on material, tool condition, and part geometry — we verify every job with CMM and GD&T inspection.
What file formats do you accept for quotes?
We accept STEP, IGES, DXF, and PDF drawings. Include material specification, quantity, tolerance requirements, and any applicable standards (ANSI, ISO, DIN) with your request.