A collaboration between Envalior, SENTImotion, and Frencken Group has led to a major leap in robotics manufacturing. The partnership has unveiled a new gearbox design, built around high-performance plastic components, that enables the efficient and cost-effective mass production of lightweight, energy-saving robotic systems.
Unveiled at the Automatica trade fair in Munich, the new system—named SMFdrives—utilizes components molded from Stanyl® PA46, a durable polyamide material developed by Envalior. Compared to traditional metal gearboxes, these plastic units weigh about 50% less and cost roughly half as much to produce at scale, thanks to precision injection molding processes. Despite their lightweight construction, the gearboxes offer the strength and wear resistance needed for long-term use in robotic applications.
While AI software continues to advance rapidly, hardware costs have remained a significant barrier to mainstream robotics deployment. The new gearbox technology is poised to change that. By significantly reducing the price and weight of robotic joints, the development could help bring full-featured robots to broader markets, including domestic, retail, logistics, and healthcare settings. Production costs for complete robots could drop toward the $10,000 threshold, enabling wider use.
“This innovation helps bridge the gap between smart robotics and affordable implementation,” said Dr Tamim Sidiki, Segment Innovation Manager for Mobility at Envalior. The development partners now plan to scale up production and begin large-scale projects with robot manufacturers. Their initial focus is on humanoid and service robots, but plans are underway to adapt the gearboxes for more demanding industrial applications as well.
“We’ve reached the point where SMFdrives is ready for commercial production,” said Steffen Breuninger, Managing Director of SENTImotion GmbH. “Our goal is to supply a new generation of efficient, adaptable gear systems across various sectors.”
Frencken Group, responsible for manufacturing the components, brings expertise in precision molding and global logistics, ensuring reliable delivery to robot manufacturers worldwide. “Our facilities are set up to meet tight tolerance requirements and deliver large volumes efficiently,” said Ron Borger, Managing Director at Frencken IMS.
One standout feature of the SMFdrives system is its built-in anti-backdrive mechanism, which removes the need for separate braking components. This reduces both the overall weight and the number of parts required in each gearbox assembly, further lowering cost and simplifying design. Additionally, the gearboxes are designed to match the form factors of traditional metal units, making them easy to integrate into existing robot platforms without redesign.
The SMFdrives gearboxes offer high torque capacity and excellent reduction ratios—key qualities for robotic motion control. Envalior’s material engineering team selected specific grades of Stanyl® PA46 known for their strength, stiffness, and fatigue resistance, even under elevated temperatures. The plastic also provides superior resistance to wear, friction, and corrosion.
Compared to traditional solutions, the combination of high-performance polymers and SENTImotion’s precision tooth geometry results in gear systems that outperform many older plastic-based designs and rival metal in mechanical reliability.
Unlike metals, plastics allow engineers to embed features such as mounting points and fasteners directly into the molded parts. This eliminates secondary manufacturing steps like machining or polishing, significantly reducing production time and cost. The result: fewer components, faster assembly, and ready-to-use parts straight from the mold.
Gearboxes often make up half the total cost and weight of a robot arm. With plastic alternatives, weight can be cut by over 20%. A lighter arm means less power is needed for movement, reducing energy consumption and increasing responsiveness.
This improved dynamic behavior also enhances robot safety. The arms can move faster while staying within safety limits defined by the ISO/TS 15066 standard for human-robot interaction. In fact, the performance of the new gearboxes exceeds current safety benchmarks, potentially setting a new bar for future robotics regulations.
Established in 2023, Envalior was formed through the merger of two leading engineering material manufacturers and employs over 4,000 people worldwide. Focused on markets such as Automotive, New Mobility, Electronics & Electrical, and Consumer Goods, Envalior is dedicated to driving customer-centric innovation and shaping a more sustainable future.
