PM gear rolling densification is a post-sintering process in which the porosity is closed at the surface and at some depth into the flank of the gear. It results in improved mechanical properties such as higher contact strength, but can also be used to improve tolerances. The optimization of the rolling process, the design of the tool geometry, the gear preform and the overall process is time consuming. Therefore, FE simulations are used to optimize the overall process and reduce the development time.