Prof. Dr.-Ing. Karsten Stahl,
Full Professor, Institute of Machine Elements, Director, Gear Research Center (FZG), TUM School of Engineering and Design, Technical University of Munich, Garching, Germany
Driving gear innovation: Interview with Prof. Karsten Stahl
From precise design and advanced simulation to highly optimized manufacturing processes and the rise of innovative plastic gears, the field of gear technology is continuously evolving. Artificial intelligence is playing an increasingly role – not only in design and simulation but also in condition monitoring and product development.
At the International Conference on Gears in Garching, experts from academia and industry gather to exchange ideas and explore these cutting-edge challenges and innovations. We spoke with conference chair Prof. Karsten Stahl from the FZG to get insights into the key trends shaping the future of gear technology.
Gears are the backbone of many machines. From your perspective, what are the most exciting developments currently shaping gear design, performance, and reliability?
From my perspective, it’s difficult to single out individual highlights in the development of gears. Rather, the current research landscape is characterized by a wide range of opportunities to enhance gear performance. These begin with advanced development methods, extend through innovative manufacturing technologies, and reach into the many possibilities for optimizing and monitoring gear operation during service.
Artificial intelligence is a big aspect in every industry and will be a topic in this year’s opening session. What role do you see AI playing in the future of gear research and applications?
AI has become an integral part of virtually all aspects of gear development, manufacturing, and operation. There are countless opportunities to leverage AI in conjunction with existing data. One of the key challenges, however, lies in providing suitable and reliable datasets. Only then will we be able to fully realize the practical potential of AI in the field of gear technology.
Engineers must balance load requirements, efficiency, durability, and noise behavior, using advanced simulation tools and even AI-based methods to refine tooth geometry and system integration. At the same time, manufacturing continues to evolve.
Today, gear design is largely a multi-parameter optimization task. Modern design tools and manufacturing technologies – such as 5-axis milling or additive processes like sintering and injection molding – offer a wide range of possibilities that were previously limited. To fully exploit this design freedom and find true performance optima, AI tools have become increasingly essential.
Plastic gears have made significant advances recently. And as we have one track focusing on that, what new opportunities and challenges do they bring?
Plastic gears are becoming increasingly high-performing - thanks to modern high-performance materials as well as the possibilities offered by intelligent design. For example, advanced design tools now allow us to account for the viscoelastic behavior of the material, enabling load-deformation characteristics to be optimally matched to the application. Naturally, the methods and standards for calculating the service life of plastic gears must evolve to reflect these new insights.
What makes the International Conference on Gears such a vital platform for the global gear and transmission community?
All these topics will be addressed at the International Conference on Gears through presentations by experts from industry and academia. In more than 120 talks, leading gear specialists will present the latest developments in technology and research. The breaks and evening event offer excellent opportunities for engaging discussions among an international community of gear enthusiasts. Nowhere else can you dive so deep into the world of gears and still have such a good time with fellow enthusiasts, colleagues, and friends who actually enjoy discussing gear topics over dinner.
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