How A Robotics Automation Company Enhanced Performance with Custom 3D Printed Dual-Layer Gears

​Introduction​

A leading robotics automation company based in Switzerland approached Yuesun3D with a critical design challenge. Their advanced robotic systems required compact, high-precision gear systems that could handle significant torque while maintaining minimal backlash. Traditional gear manufacturing methods were limiting their design innovation due to space constraints and the inability to create complex internal geometries. They needed a manufacturing partner who could produce custom gear solutions that would enable more compact robotic joint designs without compromising performance.

Addressing Space and Performance Constraints in Robotic Design

The robotics company specialized in collaborative robots for industrial applications where space optimization was crucial. Their existing gear systems occupied excessive space in robot joints, limiting range of motion and design flexibility. Standard gears couldn’t accommodate the complex torque requirements while maintaining the compact form factor needed for their next-generation robots. The company required a solution that could integrate multiple gear functions into a single, space-efficient component while providing precise motion control.

Yuesun3D’s ​Custom 3D Printed Dual-Layer Gears​ offered the perfect solution. The ability to create integrated gear systems with complex internal structures and optimized tooth profiles addressed their core technical challenges. The robotics company was particularly impressed by the capability to produce gears with different materials for each layer, optimizing performance characteristics.

Technical Collaboration and Advanced Engineering

The project involved close engineering collaboration between Yuesun3D’s technical team and the robotics company’s design engineers:

• ​Design Innovation:​​ Developed integrated dual-layer gear systems that reduced space requirements by 40% while maintaining torque capacity
• ​Material Optimization:​​ Used different polymer composites for each gear layer, optimizing for strength, wear resistance, and noise reduction
• ​Precision Manufacturing:​​ Achieved gear meshing tolerances within ±0.03mm, ensuring smooth operation and minimal backlash in precision applications
• ​Testing Protocol:​​ Implemented comprehensive testing including torque capacity analysis, longevity testing, and environmental resistance validation
• ​Rapid Prototyping:​​ Delivered functional prototypes within 5 days, enabling rapid design iteration and optimization

Transformative Impact on Robotic Performance and Design

The implementation of ​Custom 3D Printed Dual-Layer Gears​ delivered exceptional results for the robotics company. Their robotic joints became 35% more compact while maintaining the same torque capacity, enabling greater design flexibility and improved range of motion. The company reported a 50% reduction in assembly time as the integrated gear systems eliminated multiple components and simplified the assembly process.

The performance of the custom gears exceeded expectations, with significantly reduced noise levels and improved operational smoothness. The ability to customize each gear layer for specific functions allowed for optimized performance characteristics that weren’t possible with traditional manufacturing methods.

Financially, the robotics company achieved annual savings of approximately €300,000 through reduced material costs, simplified assembly processes, and decreased inventory requirements. The improved gear performance also led to longer maintenance intervals and reduced warranty claims.

The success of this partnership has expanded to include all gear-driven components in the company’s product line. They are now exploring using Yuesun3D’s capabilities for other custom mechanical components and integrated systems.

This case demonstrates how additive manufacturing can transform mechanical component design in robotics, enabling innovation that was previously impossible with traditional manufacturing methods while simultaneously improving performance and reducing costs.

For robotics companies and industrial equipment manufacturers seeking advanced gear solutions, explore our capabilities in producing custom industrial gear systems bulk orders.