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Engineering Materials

Delivering high-performance gears for compact electric engine actuators

Automotive brands are under pressure to comply with vehicle emission regulations. More OEMs are leveraging electric engine actuators that improve fuel efficiency. Yet, finding material solutions ideal for producing thin and reliable actuator gears is a challenge. 

OEMs require actuators that are highly durable, and sufficiently compact to fit in the vehicle’s engine bay. For engine actuator suppliers, this means developing parts using material solutions that respond to customers’ design and performance requirements. A key challenge to meeting these needs is finding a material suitable for producing small-sized gears that fit into compact actuator designs and operate well in high-temperature under-the-hood conditions.

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Understand why Stanyl® PA46 is a proven automotive actuator solution

Polyphthalamides (PPA) traditionally used to manufacture gears aren’t durable enough for compact actuator gears. While additional design effort can strengthen the material, these processes are expensive and result in bulky gears. 

Stanyl® PA46, an industry-leading high-temperature aliphatic polyamide, has been used in the automotive industry for over 20 years and offers: 

  • Best-in-class thermal, creep and fatigue resistance 
  • Outstanding durability in high torque applications
  • Excellent mechanical performance preventing gear failure
  • Inherent wear and friction properties eliminating the need for material enhancing additives
  • Superior flow properties enhancing design flexibility
  • Up to 40% less material required for molding gears

Explore DSM grades for gears in engine management actuators

Stanyl® TW278F10

50% Glass Reinforced

Stanyl® TW278F10 is a friction-modified high heat polyamide that offers excellent creep resistance, strength, stiffness and fatigue resistance especially at high temperatures in combination with cycle-time advantages and excellent flow. TW278F10 has an excellent track-record in gear applications.

Stanyl® TW278F10 is a friction-modified high heat polyamide that offers excellent creep resistance, strength, stiffness and fatigue resistance especially at high temperatures in combination with cycle-time advantages and excellent flow. TW278F10 has an excellent track-record in gear applications.

Stanyl® TW278F10 is a friction-modified high heat polyamide that offers excellent creep resistance, strength, stiffness and fatigue resistance especially at high temperatures in combination with cycle-time advantages and excellent flow. TW278F10 has an excellent track-record in gear applications.

  • Heat Stabilized
  • Wear and Friction Modified

Stanyl® TW341

Stanyl® TW341 is a V2 UL-rated, non-reinforced high heat polyamide that offers excellent wear & friction properties in combination with outstanding creep resistance, strength, stiffness and fatigue resistance especially at high temperatures in combination with cycle-time advantages and excellent flow.

Stanyl® TW341 is a V2 UL-rated, non-reinforced high heat polyamide that offers excellent wear & friction properties in combination with outstanding creep resistance, strength, stiffness and fatigue resistance especially at high temperatures in combination with cycle-time advantages and excellent flow.

Stanyl® TW341 is a V2 UL-rated, non-reinforced high heat polyamide that offers excellent wear & friction properties in combination with outstanding creep resistance, strength, stiffness and fatigue resistance especially at high temperatures in combination with cycle-time advantages and excellent flow.

  • Heat Stabilized
  • Lubricated

Stanyl® TW271F6

30% Glass Reinforced

Stanyl® TW271F6 is a friction-modified high heat polyamide that offers excellent creep resistance, strength, stiffness and fatigue resistance especially at high temperatures in combination with cycle-time advantages and excellent flow. TW271F6 has an excellent track-record in gear applications.

Stanyl® TW271F6 is a friction-modified high heat polyamide that offers excellent creep resistance, strength, stiffness and fatigue resistance especially at high temperatures in combination with cycle-time advantages and excellent flow. TW271F6 has an excellent track-record in gear applications.

Stanyl® TW271F6 is a friction-modified high heat polyamide that offers excellent creep resistance, strength, stiffness and fatigue resistance especially at high temperatures in combination with cycle-time advantages and excellent flow. TW271F6 has an excellent track-record in gear applications.

  • Heat Stabilized
  • Wear and Friction Modified

Browse high performance plastic gear applications

EPS Steering components: Gears, Flex couplers and Sensors

Automotive | Steering EPS

Stanyl® PA46 allows for light weight solutions (17% less weight than a metal alternative) and for sustainable solutions (NVH significant lower compared to metal); Stanyl PA46 allows for reliable solutions due to its low friction and high abrasion resistance performance

EPS gears

Automotive | Steering EPS

Stanyl® PA46 allows for lightweight and cost effective solutions as compared to machined cast metal and also offers advantages in NVH ; Stanyl® PA46 allows for reliable solutions due to its superiority in fatigue performance as compared to PA66; Stanyl® PA46 allows for cost effective solutions due to its faster cycle times in comparison with PA66 and PPA

Contact us for more information

Direct and easy access to our broad portfolio of high-performance plastics: find your grade or order a sample. You can also simply contact our Gears experts.

Find your Grade

Get your material grade selection based on torque, gear design and main boundary conditions, i.e. rotation speed and lubrication conditions. 

Request a Sample

DSM provides samples of selected products. Order a sample and find out more about our high performance plastics in Gears applications.

Contact our Gear Experts

If you can't find what you are looking for or need more help, please contact us here and we'll get in touch with you soonest.
 

Gain more gears innovation insights

  • Delivering high-performance gears for compact electric engine actuators

    Global automotive engine manufacturers require actuators that are highly durable, and sufficiently compact to fit in vehicles engine bays. For engine actuator suppliers, this means developing parts using material solutions that respond to customers’ design and performance requirements. A key challenge faced when meeting these needs is to find a material suitable for producing small-sized gears that fit into compact actuator designs and operate well in high-temperature under-the-hood conditions.

  • Tech Talk: Advanced material selection for automotive gears & actuation

    Engineers have faced the challenges of lightweighting gears and actuation systems at temperatures higher than 120°C without compromising on performance. During this 30-minute Tech Talk, key recommendations will be given based on experience working with global automakers on advanced thermoplastic material solutions for gears and actuation systems.

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