Monaghan Tooling Group plays a vital role in supporting the gear manufacturing industry by providing advanced gear cutting solutions through its partnership with Vergnano.

Advanced gear cutting solutions are a must-have advantage for any company wanting to navigate the ever-evolving gear-manufacturing landscape.

That can mean more than just offering the best the industry can get. It oftentimes means giving an extra layer of service and commitment.

Monaghan Tooling Group plays a vital role in supporting the gear manufacturing industry by providing advanced gear cutting solutions, according to Kelly Burns, VP Sales & Engineering at Monaghan Tooling.

“Through our partnership with Vergnano, we supply high-quality hobs, taps, broaches, and threading tools — engineered specifically for precision and durability in gear production,” he said. “Our approach is built on industry expertise, strong customer relationships, and responsiveness. By offering fair pricing, short lead times, and in-house design and production control, we help gear manufacturers complete their projects on time, within budget, and to specification. Whether it’s for automotive, aerospace, or industrial gears, Monaghan delivers the tools and technical support that gear manufacturers need to maintain performance and efficiency on the shop floor.”

Monaghan serves a bridge between the latest tooling advancements and real-world shop floor performance. (Courtesy: Monaghan Tooling Group)

Solving complex engineering challenges

Part of that expertise comes from being able to solve complex engineering challenges through innovative thinking, technical expertise, and close collaboration, according to Burns.

“We are not just a tooling supplier — we are problem solvers,” he said. “Our customers rely on us to help them overcome their most difficult manufacturing obstacles, and we take pride in delivering practical, results-driven solutions that work.”

Monaghan is able to give its customers the best by partnering with world-class manufacturers who are experts in their fields and serve as their sales and technical support arm in the U.S., according to Burns.

“This collaborative model allows us to act as a true extension of our partners, delivering their capabilities and knowledge directly to our customers with hands-on support and local responsiveness,” he said.

Monaghan works side-by-side with Vergnano to provide gear manufacturers in the U.S. with expert-level tools, technical insight, and responsive service. (Courtesy: Monaghan Tooling Group)

Partnering with Vergnano for gear needs

This business model becomes evident as Monaghan continues to make inroads into the gear-manufacturing industry as well, according to Burns.

“In the gear-manufacturing sector, this philosophy is fully embodied through our partnership with Vergnano,” he said. “Just as we have done for decades with other precision tooling partners, we work side-by-side with Vergnano to provide gear manufacturers in the U.S. with expert-level tools, technical insight, and responsive service. This ensures that customers benefit from both the global excellence of Vergnano and the local support and problem-solving ability that Monaghan Tooling Group is known for.”

Part of Monaghan’s mission is to make sure it keeps up with an industry that is constantly evolving, according to Burns.

“As manufacturing has advanced, so has Monaghan Tooling Group,” he said. “We’ve adapted alongside the industry through continuous engagement with new machine technologies, cutting tool innovations, materials, and coatings. Understanding these evolving capabilities is essential — not just to keep pace, but to stay ahead. Our role is to help customers make sense of these changes.”

Through its partnership with Vergnano, Monaghan supply high-quality hobs, taps, broaches, and threading tools. (Courtesy: Monaghan Tooling Group)

Bridge between advances and the shop floor

Monaghan serves a bridge between the latest tooling advancements and real-world shop floor performance, according to Burns. By staying current with trends and benchmarks, Monaghan can enable its customers to quote more competitively, implement continuous improvement effectively, and run high-quality parts across all shifts — regardless of operator experience.

“This forward-thinking approach ensures that our customers remain productive, profitable, and prepared for what’s next in manufacturing,” he said.

Challenges in a customer’s needs are a frequent occurrence at Monaghan, according to Burns, so much so that the company has developed a structured approach called “The Innovative Solution Process.”

“This six-step process ensures we not only understand the problem but also deliver a complete and lasting solution — from concept to post-installation support,” he said.

The six steps are:

  • 1. Discovery: Working closely with the customer to understand the full scope of the challenge, including current conditions and desired outcomes.
  • 2. Collaboration: Internal experts and global partners come together to analyze the situation and share insights, drawing on deep technical knowledge.
  • 3. Solution: A tailored tooling or process recommendation is developed to address the customer’s specific needs and performance targets.
  • 4. Production: Once approved, the solution moves into manufacturing, with careful attention to quality, lead time, and delivery requirements.
  • 5. Testing: The solution is validated in the field to ensure it performs as intended, with data collected and adjustments made if necessary.
  • 6. Support: Provide hands-on technical support after installation to ensure long-term success and customer satisfaction.

“This process has helped Monaghan Tooling Group deliver consistent, high-value outcomes to customers across a wide range of manufacturing challenges,” he said.

Achievements through the industries

This precise level method of approaching unique challenges gives the expert teams at Monaghan a sense of pride in the wide variety of successes the company has helped customers achieve across industries such as aerospace, automotive, agricultural, heavy equipment, and mining, according to Burns.

“Thanks to our broad range of global partnerships and technical capabilities, these achievements take many forms — from process improvements to innovative tooling solutions,” he said. “Most importantly, we are proud to be a trusted partner to manufacturing engineers and operations teams, helping them implement continuous improvement initiatives that deliver real results — on the shop floor and to the bottom line.”

Those successes through the years have come in many forms, according to Burns, but a few of them stand out and include:

  • Transforming inefficient machining processes: For example, replacing single-point boring with precision reaming to significantly reduce scrap, rework, and operator variability.
  • Producing tight-tolerance bores consistently across challenging materials and demanding applications, helping customers meet strict quality standards.
  • Designing custom lightweight tools that allow customers to machine large features while staying within the constraints of their equipment.
  • Driving continuous improvements in cycle times reduction and throughput, often resulting in rapid ROI and ongoing productivity gains.
Monaghan has expanded its capabilities by partnering with several leading tooling manufacturers. (Courtesy: Monaghan Tooling Group)

Almost 40 years of experience

Monaghan Tooling Group’s history may not be as vast as others in the industry, but the company has come a long way in its short time.

Monaghan Tooling Group was founded in 1986 by the late Dave Monaghan with a focus on producing roller burnishing tools. In its early years, the company established a strategic partnership with Elliott Tool Technologies, where Elliott handled manufacturing while Monaghan took the lead on sales, marketing, and support, according to Kelly.

“This collaboration led to the growth of a comprehensive product offering that included roller burnishing tools, OD/ID burnishing tools, internal recessing tools, expanders, and other specialized solutions — collectively known as the company’s precision metal-forming business,” he said. “Monaghan is currently owned and led by Scott Monaghan.”

As the company evolved, Monaghan expanded its capabilities by partnering with several leading tooling manufacturers, according to Kelly. These partnerships formed the foundation of what is now referred to as the High Performance Cutting (HPC) business. Key partners include:

  • Diatool: High-performance reaming.
  • MK Tools: Solid carbide drilling and milling.
  • UC Tools: PCD and CBN tooling.
  • Vergnano: Tapping, threading, hobbing, and broaching.
  • Axis: Microtooling.
  • RE-al: Reaming and floating holders.

In December 2024, Monaghan made the strategic decision to sell its burnishing business to Elliott Tool Technologies and focus exclusively on growing its HPC business. This transition marked a significant step in aligning the company’s future with advanced machining solutions and cutting tool technology.

Monaghan Tooling Group plays a vital role in supporting the gear manufacturing industry by providing advanced gear cutting solutions. (Courtesy: Monaghan Tooling Group)

Looking to the future

Burns emphasized that the company’s approach to challenges has put it on good footing to address the future of the industry and what’s next on the horizon.

“The manufacturing industry will continue to evolve—becoming faster, smarter, and more efficient, and we expect to see continued advances in machine speed, material strength, and coating technologies, all of which will place greater demands on tooling performance and application expertise,” he said. “To stay competitive, manufacturers will need partners who can keep pace with these advancements — and this is where Monaghan Tooling Group will continue to lead. We will remain a trusted adviser, helping our customers navigate change by delivering innovative tooling solutions, real-time support, and technical insight.”

Monaghan’s mission statement — Empowering Success through Innovation and Excellence — will guide the company forward, according to Burns.

“It is upheld daily by our team and grounded in our core values, which form the foundation for everything we do; these values are critical to our ability to build and sustain meaningful relationships, adapt to customer needs, and drive success in a rapidly evolving industry,” he said. Over the next decade, Monaghan Tooling Group will continue to grow as a partner of choice — one that enables customers to achieve their goals through cutting-edge technology, unmatched service, and a commitment to excellence.”