Unchanged Dimensions, 70% More Torque — Joint Webinar by Nylacast and NN

As Electric Power Steering (EPS) systems continue to evolve toward higher load capacities, torque density improvement of worm gear sets presents increasingly formidable engineering challenges. When a next‑generation DP‑EPS system requires a 70% increase in worm gear torque output while maintaining all geometric constraints — fixed centre distance, worm and worm wheel outer diameters, and tooth width — conventional design methodologies are no longer sufficient.

Nylacast Automotive and NN Inc., building on their deep collaboration since 2022, have delivered a solution.

Validated Results:

• 70% torque increase over the original design
• Additional 30% contact stress reduction
• Worm wheel outer diameter, centre distance, and tooth width — unchanged 

Our Approach:

• Stage 1 (Helical tooth form)— through systematic optimisation of tooth profile parameters, combined with Nylacast's high durability polymer material, we achieved a 40% torque increase and successfully passed Customer durability validation.
• Stage 2 (Globoidal tooth form)— the development team introduced a novel worm gear geometry, validated through CAE simulation and physical testing, ultimately achieving the 70% torque increase target.

In this presentation, we will cover the critical details of the 2-stage design optimisation: customer requirements, potential gear failure modes, design candidates considered, high fidelity CAE simulation, sample manufacture and physical testing — will be systematically presented by the technical experts in the upcoming webinar.

Joint Presenters:

• Dr. Tom Hardy | Senior Applications Engineer, Nylacast Automotive

18 years of automotive gear design experience, specialising in high‑durability polymer worm wheels for EPS systems

• Alex Clain‑Chamosset | New Business Development Manager, NN Inc.

11 years of automotive gear manufacturing experience, specialising in high‑precision worm shaft machining

This webinar is based on real‑project experience and is intended for engineering teams developing high‑load EPS systems and facing worm gear torque density bottlenecks.

📅 2026-09-22 ｜ ⏰ 9:00–10:00 AM BST

🔗 [Scan the QR Code to Register]