High-performance gears for compact and durable comfort actuator units

As consumer preferences evolve, comfort features like electrically powered seats, windows, door handles, tailgates and foldable mirrors become more important in vehicle purchases, especially in mid-class and luxury hybrid and electric models. These systems rely on compact actuators units designed for efficiency and durability. Envalior’s  Stanyl® PA46 delivers exceptional performance and reliability in gears components used in these actuator units

Challenges with traditional gear materials

Compact comfort actuators in modern vehicles demand compact gears that require durability performance at high loads and over long times. While POM and PA66 are popular materials, they can fail to meet the durability requirements especially in compact and highly stressed geartrain designs.  

Load cycle tests reveal that both POM and PA66 can have challenges with gear wear and tooth fracturing under high temperatures and high torque, leading to premature failure of the complete actuator unit. Reinforcing these materials to improve gear durability typically can in some cases result in oversized geartrain designs, which can be incompatible with design space constrains common in these actuator units. This necessitates time-consuming design adjustments, further increasing development time and development costs.

As the demand for compact, high-performing comfort actuators grows, gear manufacturers are looking for innovative and cost-effective materials that combine durability, strength, cost-efficiency and design flexibility.

Stanyl® PA46: The ideal solution for actuator gears

Envalior’s Stanyl PA46 is a high-performance aliphatic polyamide specifically designed for demanding automotive applications. It offers exceptional mechanical strength, wear resistance, and flow properties, making it the ideal choice for lightweight, thin gears used in comfort actuators.

Key Benefits of Stanyl PA46:

• Superior Torque Capacity: Stanyl PA46 gears demonstrate up to 25-50% higher torque capacity compared to PA66 and POM.
• Outstanding Thermal Resistance: At 140°C, Stanyl PA46 is about 45% stronger than PA66 and about 150% stronger than POM, ensuring reliability under high-heat conditions.
• Enhanced Design Flexibility: The material’s flow properties enable the production of compact, lightweight gears that meet stringent design requirements.

These properties make Stanyl PA46 particularly effective in high load and compact gear designs like for example worm gears, which generate significant internal frictional heat and can result in higher operating material temperature in the gear tooth contact compared with the ambient temperature conditions.

Delivering cost efficiency and long-term savings

Many manufacturers choose Stanyl PA46 as a cost-effective alternative to metal gears and high-cost solutions like polyetheretherketone (PEEK). Stanyl’s superior performance can eliminate the need for expensive wear and friction optimizers or carbon fiber reinforcements that can otherwise be needed with lower temperature materials like PA66 and POM.

Compared to reinforced PA66, POM, PPS and PPA, Stanyl PA46 achieves up to 50% higher torque capacity at 130°C, reducing the need for additional design refinements that can be required with alternative materials. This allows manufacturers to produce high-quality parts faster and more efficiently.

With over two decades of proven performance in automotive gears, Stanyl PA46 is trusted globally by OEMs, Tier 1s, and part suppliers. Annually, it is used to produce nearly 100 million gears installed in 40 million actuators in comfort, engine, cooling, and powertrain systems.

At Envalior, we don’t just provide materials; we deliver complete solutions. Our hands-on expertise in material selection, design, and application ensures that our customers meet evolving market demands while strengthening their competitive edge.

Contact us today to discover how Envalior’s advanced materials can revolutionize your comfort actuator designs and drive your business forward.