GreatLight Metal specializes in precision micro gearing, delivering innovative solutions for advanced robotic applications. Our ultra-compact worm and spur gear set, designed for a robotic hand assembly, showcases our expertise in manufacturing high-performance components for space-constrained mechatronic environments. This case study highlights our ability to deliver precision, strength, and durability in robotic hand actuation, enabling seamless fine motion control.

Project Overview

GreatLight Metal engineered a high-performance worm and spur gear set tailored for a robotic prosthetic hand. These micro gears are critical for precise finger actuation, offering unmatched reliability, torque precision, and miniaturization. By leveraging advanced CNC machining, spline rolling, and rigorous quality control, we achieved aerospace-level tolerances in a gearset smaller than a U.S. dime, demonstrating our commitment to innovation in micro-precision engineering.

Project Highlights

Key Engineering Challenges

1. Miniaturization for High Torque
   Designing a worm gear smaller than a U.S. dime while maintaining high reduction ratios and torque transmission was a significant challenge. Our engineering team optimized the gear geometry using 20Cr alloy steel to ensure robust performance in a compact form factor, ideal for robotic prosthetics.
2. Precision Tolerances for Zero Backlash
   To enable responsive finger movements, gear backlash was minimized to below 0.02 mm. Advanced CNC grinding, spline rolling, and gear lapping techniques ensured tactile precision, eliminating slack and enhancing control in the robotic hand.
3. Optimized Material Pairing
   The 20Cr steel-brass combination was chosen to reduce friction and wear under load. This pairing, combined with carburizing and cleaning processes, prevents galling, enhances lubrication retention, and ensures long-term durability in enclosed robotic assemblies.

Manufacturing Excellence

• Custom Tooling Innovation: We developed specialized form-ground tools for machining the unique worm helix angle at a micro scale and incorporated spline rolling for enhanced precision and strength.
• Comprehensive Quality Assurance: Each gear underwent:
  • 100% optical inspection for dimensional accuracy
  • Micro-hardness testing to verify HRc 58-54
  • Dual-axis tooth profile verification for flawless meshing
• Production Consistency: Achieved a Cpk > 1.67 across all critical gear features, ensuring repeatability in a 15,000-unit production run.
• Advanced Processes: Cutting, CNC machining, spline rolling, carburizing, and cleaning ensured a clean, unplated finish with optimal hardness and durability.

Application Impact

Integrated into a robotic prosthetic hand, this gearset delivers:

• Smooth, Quiet Operation: Enables precise finger articulation with minimal noise.
• High Torque-to-Size Ratio: Maximizes performance in compact designs.
• Self-Locking Stability: Ensures reliable grasp retention under load.

Feedback from our application partner praised the gearset’s “smooth meshing performance, precise tactile control, and zero slippage under high-load pinch forces,” making it ideal for advanced robotics and prosthetics.

Key Takeaways

• Micro-Precision Expertise: Proven ability to deliver sub-15mm gear solutions with aerospace-grade tolerances for robotic applications.
• Collaborative Design Process: Partnered with the robotic design team to iterate prototypes and deliver production-ready parts in under 6 weeks.
• Scalable Manufacturing: Advanced tooling and inspection systems support high-volume production of 15,000 units for next-generation wearable robotics and prosthetics.

Part Size Comparison
The image below showcases the worm and spur gear pair next to a U.S. dime, illustrating the remarkable precision and miniature craftsmanship of GreatLight’s micro gearing solutions.

Why Choose GreatLight for Precision Micro Gearing?

GreatLight Metal is your trusted partner for designing and manufacturing high-performance micro gears for robotics, wearable mechatronics, and compact actuation systems. Our expertise in advanced manufacturing processes like CNC machining, spline rolling, and carburizing, combined with a commitment to quality, ensures components that meet the most demanding specifications.

• Custom Solutions: Tailored gear designs for unique robotic applications.
• Rapid Prototyping: From concept to production in weeks.
• Scalable Production: Ready to support high-volume orders of 15,000 units with consistent quality.

Contact GreatLight Metal Today

Ready to elevate your robotic or mechatronic project with precision micro gearing? GreatLight Metal offers end-to-end solutions, from design consultation to high-volume production.

Contact Us to discuss your project or request a custom quote.
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