Cycloidal Gearbox

Designed a high-torque 21:1 single-stage cycloidal reducer optimized for smooth motion control and minimal backlash. The system uses dual cycloidal discs, an eccentric input shaft, and a pinned output ring to distribute load across multiple contact points, improving shock resistance and wear life compared to conventional spur-gear reducers. The assembly includes 100+ custom and off-the-shelf components—machined steels, bushings/bearings, precision fasteners, and alignment features—organized for efficient manufacturing and serviceability.

Developed in Fusion with full tolerance stack-ups, and DFM considerations, the gearbox achieves a projected unit cost of ~$40 at moderate production volumes, supported by standardized hardware, simplified machining, and minimal finishing operations. Intended for robotics, automation, and compact electromechanical systems requiring durable, repeatable power transmission in a low-cost package.