With high-performance motors, compact gearboxes, and high-resolution sensors, FAULHABER provides the technological foundation for advanced robotic and prosthetic hands. But how can an artificial hand be developed that does not feel like a foreign body, but instead integrates naturally into everyday life? Which requirements must be met, which challenges overcome, and which expertise applied to create a functional, intuitive, and human-centered product?
Tiziano Bordonzotti is an Area Sales Manager at FAULHABER and has been active in Global Sales for almost 30 years. With his expertise in drive technology and technical support, he has accompanied and supported numerous projects. In this interview, he shares his insights.
What requirements must drive systems such as motors and gearboxes meet to function reliably and precisely in robotic hands?
There are numerous requirements for robotic hands, as they must enable extremely precise, dynamic, and at the same time reliable movements within a very limited installation space. One of the most important characteristics is a high torque density at high speed. Motors and gearboxes must deliver sufficient force without becoming heavy or bulky. Closely related to this are precision and minimal backlash, as even the smallest inaccuracies directly affect grip quality, repeatability, and fine motor control. Efficiency and low heat generation are equally crucial. Drives are usually densely packed and often operate continuously, so hardly any waste heat can be allowed to build up. This not only protects the components but also improves efficiency and battery life.
For long-term use, drive systems must also be durable and wear-resistant. Robotic hands are often exposed to thousands of gripping cycles per day, sometimes under varying loads. Accordingly, a robust design that functions reliably even under fluctuating stresses is essential. In motorized prosthetic hands, a clear trend is emerging toward standard IP‑rated solutions. This requires the hand to be hermetically sealed and to function reliably under exposure to dirt, water, and similar environmental influences.
Another key factor is low noise generation. Quiet operation contributes significantly to a natural movement experience. In addition, fast response times and high control bandwidth are required to implement sensitive and dynamic movements. Only in this way can rapid adaptations to different objects and situations be achieved. Last but not least, size and weight are decisive. Drives must be extremely compact and lightweight. Modern drive systems must also allow seamless integration of sensors, for example for position, force, or torque feedback. Only this interaction between drive, gearbox, and sensors enables precise control and high functionality.
In summary, it is precisely these characteristics – precision, efficiency, dynamics, and reliability in minimal space – that make drive systems one of the decisive success factors of modern robotic hands.
How can high-performance yet energy-efficient drives be integrated despite limited installation space?
This is one of the central challenges in the development of modern prosthetic and robotic hands. The available space is extremely limited, while requirements for performance, precision, and efficiency continue to increase.
One of our recently won prosthetics projects clearly demonstrates what is possible today. The entire hand is highly compacted, and every available free space is utilized. This is only achievable through motors and drive components with an excellent power-to-weight ratio, combined with very well-thought-out mechanical integration. Performance, efficiency, and size must be considered together from the very beginning – isolated optimizations simply do not work in such systems.
Are there specific motor types or gearbox concepts that have proven particularly effective in your projects – and if so, why?
We are clearly seeing a trend away from classic brushed DC motors toward brushless motors. BL motors offer higher efficiency, longer service life, and are better suited for dynamic, high-load applications – exactly what modern robotic hands require. At the same time, highly resilient and extremely compact gearbox solutions play a decisive role. In several projects, customized and in some cases patented solutions for high load capacity and mechanical power transmission were developed together with our customers. Miniaturization is also becoming increasingly apparent: whereas drive units with diameters of up to 15 mm were commonly used in the past, today’s solutions are often in the range of 8 to a maximum of 12 mm – with significantly higher performance.
How important is noise reduction for drives in prosthetics or humanoid robots, and how is it implemented technically?
Noise reduction is a very important factor, especially in prosthetics and humanoid robots that operate in close proximity to humans. A loud drive is quickly perceived as unnatural or disturbing. Although noise initially originates in the motor itself, it is often further amplified by poorly designed mechanical couplings, gearboxes, or unsuitable materials. Increasing system dynamics present a particular challenge: the higher the speed and motion velocity, the higher the inherent noise level.
Technically, this can only be solved through a holistic drive concept: quiet motors, precisely manufactured gearboxes, optimized bearing arrangements, and clean mechanical integration. Only the interaction of all these factors ensures smooth operation and a natural movement feel.