Protoshop: where VCST turns requirements into validated gear solutions

A gear program starts with a requirement, not with a machine. Load and torque targets, rotational speed, and the required ratio define the solution space. The Protoshop is where VCST turns that engineering intent into real parts, fast iterations, and verified performance before anything is scaled to production.

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From requirement to design

Product development starts from customer needs. Based on the required load, torque, speed and gear ratio, we design the gear solution using calculation software.

We use in-house tools for macro-geometry and KISSsoft for micro-geometry, so we can define the macro and micro geometry, contact ratio, and safety factors for bending and pitting. From there, we prepare drawings and CAM models that form the basis for prototyping.

Prototyping in the protoshop

After the R&D development phase, the Protoshop produces prototypes in a setup that is deliberately independent from series production.

It is a lean organization with its own machines, measuring equipment, and raw material stock. That matters in practice: prototyping can continue on its own schedule, even when production capacity is fully loaded.

The Protoshop includes advanced capability such as a 5-axis machine, allowing multiple design variations to be produced and evaluated quickly. This shortens the loop between engineering questions and physical evidence.

NVH optimisation and patented solutions

Many customer challenges sit in NVH. Rattle and whine noise are often system-level effects that require targeted gear solutions.

VCST has developed and manufactured multiple patented technologies to address these issues and holds 25+ patents, including scissor-gear designs that help eliminate rattle noise from tooth impacts and shock impulses. Whine noise, linked to excitation and high-frequency behaviour, is addressed through advanced manufacturing processes and in-house tooth-shape deviation analysis. Additional patents are in development, both in gear design and in manufacturing processes.

In-house validation

Prototyping without validation is guesswork. That is why testing is done in-house, with both destructive and non-destructive capability.

Destructive testing covers material fatigue strength, including durability, pitting and tooth bending. Non-destructive testing supports NVH measurement, so solutions can be evaluated against functional behaviour, not only geometry.

Contact VCST

Want to discuss a project, prototyping support or an industrialisation approach?
Contact the VCST Sales team: sales@vcst.com