AbstractExternal gear components are used in a variety of production and manufacturing areas, including motion, energy, and power transmission in many industrial applications. Examples include transportation equipment, aerospace equipment, and machine tools such as lathes and milling machines, all of which rely on gearboxes. As a result, these components are receiving increasing attention. This paper introduces an innovative multi-level rotary ballizing technique for manufacturing toothed tubular parts in one stroke. The process was examined both experimentally and numerically. The experimental study focused on key parameters, including die rotational speed (100, 200, 315, and 400 rpm), mandrel axial feed rate (0.13, 0.15, 0.18, and 0.21 mm/rev), and cross-feed values (4.5, 5.5, and 6.5 mm), achieved using three levels of ball. Additionally, initial tube thicknesses of 6, 7, and 8 mm were analyzed. The study investigated the influence of these parameters on forming load, filling ratio, and the hardness of the formed product. The results demonstrated that these factors significantly impact forming load, filling ratio, and overall product quality. A mathematical model was developed to predict forming loads numerically, and the calculated results showed a strong correlation with experimental findings. Moreover, the experimental results confirmed the effectiveness of the proposed multi-level ballizing technique in successfully forming toothed parts with greater thicknesses while significantly reducing forming loads compared to the single level ballizing method.