Schaeffler to Mass Produce Formed Gearboxes for Humanoid Robots by 2027

Schaeffler Technologies AG will begin mass production of "formed" strain wave gearboxes for humanoid robots in 2027. The move aims to eliminate a critical supply chain bottleneck by drastically reducing the cost and time required to produce high-precision robotic joints.

Production will launch in Germany before expanding to global markets. Rather than relying on traditional subtractive precision machining, Schaeffler is implementing a high-speed forming process that uses high pressing forces to shape components in seconds. This process reduces manufacturing costs by more than 25% and cuts material consumption by more than 75% compared to traditional machining methods.

The Hardware Bottleneck

Strain wave gearboxes are essential for the sensitive joints of a humanoid, such as the wrists, ankles, and elbows, because they offer high gear reduction ratios and zero backlash in a compact form. However, the traditional manufacturing process is capital-intensive and slow, creating a ceiling for how quickly these robots can be scaled. The financial stakes are high: actuators—which include the motors, gearboxes, and controllers—can account for up to 50% of a humanoid robot's total manufacturing cost.

Schaeffler is leveraging its "automotive DNA" to pivot to this forming process, a technology it has already proven at scale. Over the last decade, the company has supplied more than 2 million formed strain wave gearboxes to the automotive market. This new humanoid line complements Schaeffler's existing portfolio, which includes all-in-one planetary gear actuators designed for high-torque joints like hips and knees.

Shifting the Competitive Edge

The ability to mass-produce high-precision actuators at a lower cost is a prerequisite for moving humanoid robots from expensive prototypes to millions of commercial units. By solving the cost bottleneck of the joints, Schaeffler is positioning itself as a primary Tier 1 supplier for the industry. This shift suggests that the competitive advantage in the humanoid race may move from AI software capabilities to the ability to manufacture affordable, scalable hardware.

"The formed strain wave gearbox is another example of how we are readying key robot components for industrial high-volume mass manufacturing," said David Kehr, President of Humanoid Robotics at Schaeffler. Kehr added that the company expects to take a "leading role" in the humanoid market.

What to Watch

While the cost and material savings are confirmed, the industry will be watching to see if these formed components can maintain the strict performance standards of machined parts in complex humanoid applications. As Schaeffler prepares for its 2027 rollout, the focus will remain on whether this manufacturing pivot can successfully drive down the overall bill of materials for the next generation of general-purpose robots.