Schaeffler Targets Mass-Market Humanoids With Scalable Gearbox Manufacturing

The formed strain wave gearboxes from Schaeffler were developed especially for humanoid robots and transmit movements precisely and with a high torque capacity and a high gear reduction ratio in an extremely compact space. (Image: Schaeffler)

(IN BRIEF) Schaeffler has introduced formed strain wave gearboxes for humanoid robots, expanding its robotics portfolio with a key actuator component designed to meet demanding requirements for precision, stiffness, compactness, high torque capacity and high gear reduction ratios in humanoid robot joints. The company said its innovative forming technology can manufacture key gearbox components in seconds instead of minutes, reducing manufacturing costs by more than 25 percent and material consumption by more than 75 percent compared with conventional precision machining. Schaeffler has completed extensive validation testing and plans to begin mass manufacturing in 2027, starting in Germany before expanding to other regions and supplying numerous humanoid robot manufacturers worldwide. The company is applying experience gained from producing more than 2 million formed strain wave gearboxes for the automotive sector over the past decade, with David Kehr, President of Humanoid Robotics at Schaeffler, saying the technology shows how the company is preparing key robot components for high-volume industrial production.

(PRESS RELEASE) HERZOGENAURACH, 13-Aug-2026 — /EuropaWire/ — Schaeffler is expanding its humanoid robotics portfolio with the introduction of formed strain wave gearboxes, a key component designed to support the industrial scaling of humanoid robots.

The new gearboxes have been developed specifically for humanoid robot joints, where precision, stiffness, compactness, high torque capacity and high gear reduction ratios are essential.

Schaeffler said the technology is intended to help make humanoid robots ready for the mass market by improving manufacturing efficiency and reducing production costs.

Strain wave gearboxes are critical parts of actuators, which account for around half of the total manufacturing cost of a humanoid robot.

These gearboxes transmit movement precisely and can deliver high torque and high reduction ratios in extremely compact spaces.

They therefore meet the central mechanical requirements of humanoid robot joints.

The strain wave gearbox manufacturing method currently established in the market is precision machining.

However, this process is time-consuming and capital-intensive, and Schaeffler said it could become a major bottleneck as humanoid robot production scales in the coming years.

Schaeffler is addressing this challenge with an innovative forming technology that enables key components to be manufactured in seconds instead of minutes.

The company said the new process reduces manufacturing costs by more than 25 percent and lowers material consumption by more than 75 percent.

Schaeffler has completed extensive validation testing of the formed strain wave gearboxes, laying the foundation for mass manufacturing to begin in 2027.

Production will initially start in Germany and then be rolled out successively to other regions.

Schaeffler said the technology will be supplied to numerous humanoid manufacturers around the world.

The company has been building expertise in the manufacture of formed strain wave gearboxes for the automotive sector for many years.

Over the past decade, Schaeffler has supplied more than 2 million formed strain wave gearboxes to all major global markets in that sector.

The company has now transferred this manufacturing knowledge to the fast-growing field of humanoid robotics.

David Kehr, President of Humanoid Robotics at Schaeffler, said the company aims to take a leading role in the humanoid robot market.

He said Schaeffler deploys humanoids across its own global value chain, giving the company direct insight into the requirements of the technology and enabling it to develop key components based on practical experience.

Kehr added that Schaeffler combines this knowledge with decades of manufacturing expertise and its automotive background to create solutions focused on quality, economic viability and scalability.

He said the formed strain wave gearbox demonstrates how Schaeffler is preparing key robot components for industrial high-volume manufacturing.

Innovative forming technology for strain wave gearboxes

Schaeffler developed the new forming process for humanoid robot strain wave gearboxes using its manufacturing technology expertise.

Unlike conventional machining, where high-precision gear geometries are created by removing material, the forming process shapes the component into the required geometry within seconds through the use of high pressing forces.

The formed strain wave gearboxes achieve comparable torques and efficiencies to conventionally manufactured components.

The method also offers high dimensional accuracy, reduces material consumption and improves process stability.

Schaeffler said the approach combines precision, efficiency and industrial scalability, creating a technological basis for the high-quality and more efficient production of key components for humanoid robots.

Through the introduction of formed strain wave gearboxes, Schaeffler is positioning itself to support the next phase of humanoid robotics manufacturing, where component availability, cost efficiency and scalable industrial production will be critical to broader market adoption.

Schaeffler Group – We pioneer motion: The Schaeffler Group has been driving forward groundbreaking inventions and developments in the field of motion technology for 80 years. With innovative technologies, products, and services for electric mobility, CO₂-efficient drives, chassis solutions and renewable energies, the company is a reliable partner for making motion more efficient, intelligent, and sustainable – over the entire life cycle. Schaeffler describes its comprehensive range of products and services by means of eight product families: From bearing solutions and all types of linear guidance systems through to repair and monitoring services. Schaeffler is with around 110,000 employees and more than 250 locations in 55 countries, one of the world’s largest family-owned companies and one of Germany’s most innovative companies.

Media Contact:

Daniel Pokorny
Head of Communications Technology, Operations & Digitalization
Tel.: +49 9132 82-88708
E-Mail: daniel.pokorny@schaeffler.com

SOURCE: Schaeffler