Pharmaceutical & medical
high speeds and low torque, which is unsuitable for direct surgical actuation.
Gearboxes resolve this issue by stepping down the rotational speed and increasing torque, enabling robotic tools to grip, rotate or manipulate with the delicacy required during procedures on soft tissue, nerves or within vascular structures. Gear reduction also enhances stability and motion repeatability, enabling surgical robots to perform with consistent accuracy. But not just any gearbox will do. Off-the-shelf gearboxes are often too large to be integrated into compact surgical systems, particularly those designed to operate within the human body. They may also introduce backlash or torque ripple. These are small inconsistencies that, while acceptable in industrial machinery, could be the difference between success and complication in surgery. Material compatibility is another issue. Gearboxes used in medical devices may need to be built from biocompatible or sterilisation-resistant materials. For these reasons, custom gearbox solutions are needed. Not just to meet torque and speed specifications but to ensure precise fit, predictable performance and long- term reliability in many life-critical environments.
Instrumentation Monthly June 2025
THE CUSTOMISATION PROCESS Designing a custom precision gearbox for advanced surgical robots begins with a clear understanding of the application. Collaborating with medical professionals will help establish whether the gearbox needs to deliver a catheter through fragile vessels or articulate a multi-jointed end-effector within a confined surgical site. Developing this level of application understanding allows the engineer to precisely identify the optimal solution. This identification begins with determining whether the application requires a linear actuator, which provides precise, controlled linear movement, or a rotary actuator, which delivers rotational motion with specific torque and speed characteristics. The design process then begins by defining the gear architecture, selecting gear types, gear ratios and mechanical layouts to meet precise torque, speed, motion and noise requirements. It is also important to consider the material choice here, as it should be able to withstand repeated cleaning cycles and avoid adverse reactions within the human body.
Advanced 3D modelling software then helps
bring the gearbox design to life. Software such as SolidWorks enables engineers to visualise complex geometries, simulate performance and verify spatial constraints. This detailed digital modelling ensures the gearbox integrates seamlessly within the compact and demanding environments of surgical systems before manufacturing starts.
Finally, a prototype of the gearbox will undergo rigorous testing. This is done under real-world conditions, where the gearboxes’ performance is monitored, including its torque, force, noise and environmental resistance. This stage is critical as it ensures the final product meets the exacting standard for reliability and precision and will not falter in the operating theatre.
As surgical robots continue to push the boundaries of medical innovation, the demand for highly specialised, reliable and precise gearbox solutions will only grow. Custom precision gearboxes are not just components — they are critical enablers of delicate, life-changing procedures.
EMS
www.ems-limited.co.uk 53
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