Precision Mechanical Transmission Parts
Every motion system depends on the precision of its plastic parts. Gears, bearings, and guides must be flawless—any error in shape or material becomes noise, wear, and early failure. We engineer these parts as precision instruments. Through simulation-driven design, advanced polymers, and micron-level control, we ensure your system runs smoother, lasts longer, and performs reliably. Let us build the foundation for your motion’s success.
Solution Insight
Engineering Silence: A 15dB Noise Reduction in Automotive Actuator Gears
Context & Challenge
A global automotive supplier faced critical NVH (Noise, Vibration, Harshness) issues with a window regulator actuator. The standard nylon gear generated noticeable whining noise that failed to meet luxury vehicle acoustic standards.
Key requirements: reduce operating noise by at least 10dB, maintain or improve mechanical strength and wear resistance, and fit within the existing assembly envelope and cost targets.
Our Solution
We conducted moldflow and structural analysis to identify root causes: sink marks and uneven tooth loading. We redesigned the gear tooth profile, optimized pressure angle and root fillet for smoother meshing and load distribution.
We adopted a custom glass-fiber reinforced PPA compound for better dimensional stability, higher stiffness, and natural damping. High-precision tooling and scientific molding ensured tooth profile consistency within ±5 microns, eliminating noise-causing variations.
Quantifiable Results & Client Benefits
Achieved 15dB noise reduction, exceeding the 10dB target and meeting strict luxury acoustic standards.
Fatigue life increased by an estimated 40% in accelerated testing for improved long-term reliability.
Direct drop-in replacement with no assembly modifications, enabling fast, low-cost implementation.
Helped client secure a high-value contract for a next-generation premium vehicle platform.
Get a Pro Recommendation
Tell us about your product, and we’ll suggest the best material for it.