Our Machining Projects
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Precision Machined Non-Standard Harmonic Drive Components
These are the core components of a non-standard harmonic drive we machined for a custom application. The set includes a flex spline and a circular spline, each requiring a different combination of machining processes to achieve the precision the application demands. The flex spline was completed through precision turning, while the circular spline went through an additional gear grinding process to produce the internal tooth profile.
Thin-walled parts like the flex spline and circular spline are not straightforward to hold during machining. The wall thickness is small enough that any uneven clamping force causes the part to deform slightly while it is being cut, and once you release the clamp, the part springs back. What looks like a good dimension on the machine ends up out of round once the part is free. For harmonic drive components where roundness and cylindricity directly affect how the drive performs, this is not something you can ignore.
Project Details
Part type: Custom Harmonic Drive Components (Flex Spline + Circular Spline)
Material: Alloy Steel
Machining Process: Precision Turning + Grinding + Gear Grinding
Surface Finish: As-Machined
Custom Machining Solutions
For both the external turning and gear hobbing operations, we used custom hydraulic expansion fixtures. The hydraulic expansion fixture works by expanding evenly around the full inner bore of the part when pressurized, distributing the clamping force uniformly across the entire contact surface. This keeps the thin-walled parts perfectly round during machining without introducing any clamping distortion, The result was measured runout of 0.001 mm and a repeat positioning accuracy of 0.002 mm.
Harmonic drives are used in applications that require high torque transmission in a compact form factor with minimal backlash. Non-standard harmonic drive components like these are typically needed when standard catalogue sizes do not fit the specific space constraints or load requirements of a design. In robotics and collaborative robot arms, harmonic drives are commonly used in joint actuators where precise positioning and smooth motion are critical. Custom sizes allow engineers to optimize the joint geometry for their specific robot design.
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Our Manufacturing Capabilities
Capabilities include 3-Axis, 4-Axis, and 5-Axis CNC Milling, as well as CNC Turning operations. Standard materials processed include Aluminum alloys, Stainless Steel, Titanium, etc. and Engineering Plastics. Available secondary operations include Anodizing, Powder Coating, Bead Blasting, and Laser Engraving.
Capacity supports requirements ranging from single-unit Rapid Prototyping to Low-Volume Production runs (1-1,000+ units).
Factory Quality Assurance
A standardized Quality Management System (QMS) is applied to all manufacturing orders, regardless of part complexity or production volume. The following inspection stages are mandatory for every CNC machining project:
Order Fulfillment Process
From CAD to part.
