Optimizing gears for next-generation electric brake actuators

With the rise of connected cars, electric braking systems are transforming safety and performance. Electric brake boosters and electric parking brakes relying on gear drives offer precise control and efficiency and are growing rapidly, with projected CAGRs of 26.4% and 17.2% by 2026. Envalior’s advanced thermoplastics, including Stanyl® PA46, deliver lightweight, durable solutions for high-performance gears used in these electric braking systems.

Electric brake systems demand exceptional performance from actuator gears, particularly in applications like automatic emergency braking, where high torque levels create significant component and material stresses. Common materials such as polyamide 66 (PA66) and polyoxymethylene (POM) often fall short of meeting these demands when high load and high durability needs are combined with compact gear design requirements, which is often the case with these actuator units.

Under heavy loads, PA66 and POM gear teeth are prone to cracking or deformation, resulting in compromised performance and reduced reliability. The thermal degradation of these materials further compounds the issue. Frictional heat generated during operation can cause gear teeth to weaken or melt, especially in high-temperature conditions like those found in some high load worm gear designs sometimes seen in electric brake actuators.

Efforts to reinforce PA66 and POM to improve durability often result in large and thick gear designs. These oversized gears sometimes fail to meet the compact design requirements of electric brake actuators, limiting their usability in space-constrained environments.

These limitations not only increase the risk of gear failure but also pose safety concerns, potentially leading to brake malfunctions with severe consequences. To meet the evolving demands of next-generation brake-by-wire systems, manufacturers must turn to advanced materials that offer enhanced reliability, compactness, and cost efficiency.

Driving efficiency and cost savings

Stanyl PA46 not only enhances gear performance but also offers additional advantages:

• Reduced space requirements: Allows up to 25% reduction in gear size within actuator housings, without compromising durability or performance.

• Lower production costs: Unlike some specialty PA66, POM and PPA compounds (e.g., that can require costly carbon fiber or wear & friction optimizers), standard and cost-effective Stanyl PA46 grades often achieve performance without the use of additional and costly additives.

• Faster production cycles: The material’s high crystallization speed and high flow properties helps speed up gear manufacturing, improving manufacturing cost efficiency.

By leveraging Stanyl PA46, gear suppliers can differentiate themselves in the market and deliver high-quality parts more efficiently.

With over 20 years of experience in automotive applications, Envalior is a trusted partner to leading OEMs, Tier 1 suppliers, and gear manufacturers worldwide. Each year, Stanyl PA46 is used to produce approximately 100 million gears installed in 40 million actuators for electric braking, comfort, engine, cooling, and powertrain systems.

At Envalior, we provide hands-on support, from material selection to application optimization, ensuring our customers achieve their design and performance goals.

Ready to elevate your gear designs for electric brake actuators? Contact Envalior today to discover how our advanced material solutions can help you deliver reliable, cost-effective components that exceed OEM expectations.