A conceptual examination of an additive manufactured high-ratio coaxial gearbox

This research introduces the novel “Kraken-Gear” mechanism, emphasizing the advantages of additive polymer 3D printing in high-ratio gearbox systems for lightweight robotic applications, such as surgical instruments. The innovative kinematic solution provides high torsional system stiffness, substantial gear ratios, and backlash-free transmission. Leveraging the “hot lithography” additive manufacturing method ensures precise and warp-free gearbox components. Targeting medical technology, the gearbox meets stringent requirements: backlash-free, minimal vibration, high precision, and torque, with minimized weight for ergonomic comfort and fatigue mitigation. Computational simulations assess forces and stresses, highlighting the potential of additive manufacturing for cost-effective and functionally efficient gearbox fabrication. Nevertheless, careful material selection remains imperative for optimal functionality, especially in demanding medical applications. In summary, this research underscores a promising approach to gearbox fabrication, emphasizing the critical role of material selection and simulation-based assessments for optimal performance.