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Engineering Materials

Gears for compact electric engine actuators

Our innovative high-performance plastics are developed to meet a wide variety of technological challenges in automotive. Browse these pages to learn more about how our industry experts, scientists and engineers work hand in hand with our customers to develop next generation solutions.

Maximizing durability & optimizing cost ​in constrained design spaces

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.

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 

Learn why plastic is the material of choice for gears

How to engineer a greater gear

In DSM's state-of-the-art materials science centers, we place strong emphasis on understanding both the theoretical and practical relationship between an application and a material’s wear and friction properties. In this video, learn about the various gear test methods we use to better simulate actual conditions.

 

 

 

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An introduction to choosing the right materials for gears and actuators

In this video, Martin Wolffs, product manager at DSM, explains the benefits of using high-performance polyamides in gear applications, and why the tooth temperature of a gear is a key property for choosing the right gear material.

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

Grade selector for Gears

Explore our most popular 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

Contact us for more information

Direct and easy access to our broad portfolio of high-performance plastics: request a quote or order a sample. You can also simply ask us a (technical) question. 

Read related blogs

  • 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.

  • Can annealing improve material performance and lifespan?

    Finding the right balance in between manterial requirements has caused many manufacturers to avoid secondary processing steps such as annealing. However, annealing can result in a significant improvement on a part’s performance, and in this blog we’d like to dive a little deeper into the annealing process, its benefits and attention points.

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