More precision, less friction: Strain wave gearheads for sensitive applications

When it comes to precise motion control and high torque transmission in minimal space, strain-wave gear technology is indispensable. Darko Lukic, Head of Development Gears at maxon, explains why these precision components expand the company’s portfolio and what advantages they offer for demanding applications.

maxon has added strain-wave gears to its portfolio. What does this mean for motion control applications?

Darko Lukic: With strain-wave gears, we can offer highly precise and compact drive solutions from a single source – including motor, gear, encoder, and controller. This reduces integration effort, lowers technical risks, and speeds up time-to-market. For developers, this means less time spent on drive design and more focus on the actual application.

What specific advantages do these gears offer in applications requiring maximum precision and compact design?

Darko Lukic: Our strain-wave gears feature up to 50% lower no-load friction, which improves energy efficiency and enables sensitive movements. With efficiencies of up to 80%, they are well above the industry average. Additionally, they offer backlash-free operation, quiet performance, and long service life – all crucial for sensitive environments. A practical benefit: customers can source complete drive systems directly from us, greatly simplifying integration.

How does the gear design principle support high torsional stiffness and efficiency?

Darko Lukic: The core component is the flexible flexspline, which, together with the rigid circular spline, enables backlash-free power transmission. The optimized tooth profile and precise manufacturing reduce friction and increase torsional stiffness – ensuring maximum efficiency and stability.

In which fields are strain-wave gears primarily used?

Darko Lukic: Mainly in robotics and medical technology, but also in aerospace, optical systems, and semiconductor manufacturing. Wherever precision, compactness, and reliability are essential.

Which technological innovations have improved performance?

Darko Lukic: These include optimized tooth profiles, new materials and lubricants, tighter manufacturing tolerances, and larger wave bearings and gearings with the same outer diameter. These advancements result in less friction, reduced wear, and higher precision.

How does maxon support engineers with integration?

Darko Lukic: We supply complete, matched, and assembled drive units. We also provide CAD data and 3D models. In addition, our engineers offer application support to make integration as easy as possible.

What sets maxon apart from other providers?

Darko Lukic: Our unique selling point is the combination of strain-wave gear, motor, encoder, and controller – all from a single source. A major advantage of the maxon portfolio is that all components can be perfectly matched. Added benefits include lower friction torque, higher efficiency, and renowned Swiss precision.

What does the future of strain-wave gears at maxon look like?

Darko Lukic: We’re working on miniaturization for microrobotics, integrated sensors for condition monitoring, expanded sizes, and customized solutions. This allows us to open up new application areas and strengthen our positio