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DSM in Automotive

Gearing up for weight and cost savings

Starter motor gears are a demanding automotive application – which is why we worked with a leading manufacturer to develop a product based on our Stanyl® polyamide 46 that (appropriately enough) reduced weight by 46 per cent compared to a traditional metal gear.
Men looking through his hands with one eye closed

Making the move to plastic annulus gears from metal saves weight – but it also delivers a host of other benefits, not least cost savings. For example, starter motors built using Stanyl are built to last, providing exceptionally low wear rates in demanding under-the-hood environments, all while significantly reducing system costs.

When we collaborated with one of the industry’s biggest names in gears it specifically helped cut costs in three ways: Reducing the part count from five to one; eliminating assembly steps and thus improving cycle time; and reducing injection molding cycle times.

The result: Decreased overall system costs and lower carbon footprint (after all, less weight and more efficient engines equals less fuel consumption).

So how does it work?

With the adoption of demanding start/stop starter motors, annulus gears need to cope with an enormous increase in load cycles.

To put that in perspective, conventional starter motors handle up to 40,000 engine starts or 13 million load cycles per gear tooth. However, for the newer start/stop starter motors this is jumping to a huge 350,000 starts or 45 million load cycles - all under higher temperatures than ever.

Stanyl is proven to cope with this increased workload thanks to its ability to perform consistently long term at extreme operating temperatures of up to 170°C.

When it comes to starter gears, the plastic revolution has truly…started.

Learn more about how DSM can help you improve efficiency in engines and part production