Schaeffler to Begin Large‑Scale Production of Formed Strain‑Wave Gearboxes for Humanoids in 2027

Schaeffler announced that it will begin large‑scale production of its formed strain‑wave gearboxes for humanoid robots in 2027, with the first line located in Germany. The company positions the new gearboxes as a core component of actuator assemblies, which it says represent roughly half of the total manufacturing cost of a humanoid robot.

Key takeaways

  • Mass manufacturing of formed strain‑wave gearboxes is slated to start in Germany in 2027 and will later expand to other regions.
  • The high‑speed forming process reduces component cost by more than 25 % compared with traditional precision machining.
  • Material consumption drops by more than 75 % and the machining step shrinks from minutes to seconds.
  • The gearboxes deliver torque, efficiency and dimensional accuracy comparable to machined parts.
  • Schaeffler has already produced over two million formed strain‑wave gearboxes for the automotive market, giving it a decade‑long production base.
  • The global precision‑gearbox market was $3.58 B in 2025 and is projected to reach $9.40 B by 2034 (CAGR 9.98 %).
  • Robotics accounts for 40 % of that market, while planetary gear technology holds 50 % of revenue in 2025.
  • Bosch will launch series production of its HMND Gamma humanoid robot in August 2027 at the Bühl plant, the first European humanoid line.

Formed strain‑wave gearboxes – a manufacturing shift

Traditional strain‑wave gearboxes are made by precision machining, a subtractive process that removes material to create high‑precision gear geometry. Schaeffler replaces that approach with a high‑pressure forming technology that stamps the component into its final shape. The company describes the method as “high‑speed forming” and notes that it pivots away from the “slow, capital‑intensive precision machining.”

Cost, material and time benefits

The forming process delivers three measurable advantages:

Metric Traditional machining Formed process
Component cost Baseline > 25 % lower
Material consumption Baseline > 75 % lower
Cycle time per part Minutes Seconds

These numbers come directly from Schaeffler’s own validation data. The company stresses that the gearboxes still meet the same torque limits, efficiencies and dimensional tolerances as their machined counterparts.

Production timeline and global rollout

Validation testing of the formed gearboxes is complete, and Schaeffler says it will “start manufacturing them at scale in 2027.” The initial production line will be in Germany, and the firm plans a “gradual rollout to other global regions” after the first batch is up and running. By leveraging its existing automotive‑gearbox facilities, Schaeffler expects to transition smoothly from its historic output of over two million automotive units to the humanoid market.

Completing the actuation portfolio

Schaeffler’s gear‑driven actuation strategy now spans two complementary families. In late 2025 the company introduced an all‑in‑one planetary gear actuator aimed at high‑torque joints such as hips and knees. The newly announced formed strain‑wave gearbox fills the remaining joint segment, “secur[ing] the other half of Schaeffler's actuation portfolio, complementing the planetary gear actuators it unveiled in late 2025.”

Market landscape for precision gearboxes

The broader market context reinforces the timing of Schaeffler’s move. Industry research shows the global precision‑gearbox market was valued at USD 3.58 billion in 2025 and is projected to reach USD 9.40 billion by 2034, reflecting a 9.98 % CAGR over the 2026‑2034 period. Robotics already claims 40.0 % of gearbox revenue, and planetary gear technology dominates with a 50.0 % share of 2025 sales.

Implications for OEMs and production lines

The first European humanoid production line is scheduled to start in August 2027 at Bosch’s Bühl plant, building the HMND Gamma robot under a contract with the Humanoid startup. The plant employs roughly 2,700 people, with about 1,100 positions slated to disappear by 2030, though a collective‑bargaining agreement currently bars compulsory redundancies through the end of 2027.

Outlook

Schaeffler’s decision to shift from machining to forming, combined with a clear production schedule for 2027, provides a new supply‑side option for humanoid robot manufacturers. When the German line comes online, manufacturers will have access to mass‑produced, cost‑reduced strain‑wave gearboxes that meet the performance levels required for humanoid joints.

All statements above are based on company announcements, market research, and related reporting.

Sources

This article was researched and fact-checked against the following sources: