A 70% Torque Leap with Zero Size Change? The Physical Barrier is Broken

Facing rigid packaging space challenges but requiring 40-70% higher torque for a next-generation Dual Pinion-EPS worm wheel, a global Tier-1 turned to Nylacast Automotive. The challenge: fixed center distance, no increase in outer diameter or tooth width.

Our two-stage tooth profile design delivered the impossible:

Stage 1: Optimised Helical Tooth Profile

✅ 40% torque increase achieved

✅ Passed customer durability validation

✅ Balanced bending, shear & contact stresses via FEA

Stage 2: Globoidal Worm Gear Solution

✅ 70% torque increase – target shattered!

✅ Additional 30% stress reduction

✅ Customer assembly process modified for superior performance

This step-change in torque density combines optimised tooth profiles, globoidal gear tooth forms, high-durability polymer, and precision machining.

As Dr. Tom Hardy, our gear design expert with 17 years of experience, notes: “This keeps Nylacast Automotive at the forefront as the industry moves to ever higher rack forces and worm wheel tooth loads!”

Interested in pushing the boundaries of your steering system performance?

👉 Discover the full technical breakthrough on our website: Nylacast Automotive