Challenges of compact actuator gear manufacturing

Compact actuator gears need to perform under demanding conditions, including high heat and torque, while maintaining durability over time. Traditionally, polyphthalamide (PPA) has been a common choice for these gears. However, PPA’s limited durability poses challenges, especially in small or thin designs required for compact actuators.

Under high torque and temperature, PPA gears may wear out or fail prematurely, potentially leading to actuator malfunctions, costly repairs, or recalls. While additional design modifications can enhance PPA’s durability, these efforts often increase gear size, production time, and costs, which conflict with OEMs’ compact design requirements.

This has prompted manufacturers to seek alternative materials that combine superior performance, cost-effectiveness, and compatibility with compact actuator designs.

Stanyl® PA46: A proven solution for actuator gears

Envalior’s Stanyl® PA46 is a high-performance semi-crystalline aliphatic polyamide tailored for demanding under-the-hood applications. This material offers:

• High fatigue and creep resistance: Maintains outstanding mechanical properties in extreme conditions.
• Excellent wear and low friction: Ensures long-term reliability in gears subjected to high torque.
• Superior flow properties: Simplifies the production of thin, lightweight gears that meet tight design specifications.

Stanyl® PA46 enables manufacturers to achieve compact, efficient, and reliable gear designs without sacrificing performance or increasing costs.

Benefits of Stanyl® PA46 for gear manufacturing

Stanyl® PA46 delivers substantial advantages over alternative materials, including:

• Reduced material usage: Gears molded at 6mm thickness with Stanyl® PA46 can offer similar performance as 10mm thick PPA gears, reducing space requirements by up to 40%.
• Cost efficiency: The material can in some designs eliminate the need for costly fillers like carbon fiber, helping reduce material costs by more than 10%.
• Enhanced durability: Stanyl® PA46 demonstrates superior resistance to tooth flank wear and tooth root fractures, ensuring longer part lifetimes.
• Improved weight and noise reduction: Lighter and quieter than metal alternatives, the material enhances overall actuator performance.

These benefits make Stanyl® PA46 the optimal choice for gears used in high temperature engine management actuators, offering a balanced combination of performance, cost savings, and design flexibility.

With over 20 years of experience in automotive applications, Envalior collaborates with leading OEMs, system developers, and component suppliers worldwide. Each year, our materials are used to produce approximately 100 million gears for 40 million actuators across various vehicle applications.

To support our global partners, we provide extensive material and design expertise, helping customers optimize actuator performance and meet evolving industry demands. Partner with Envalior to develop innovative, reliable, and cost-efficient actuator components that meet the needs of modern automotive manufacturers.

Contact us today to learn how our solutions can help drive your business forward.