Likely limitation to achieve 2x torque

[spit40]

I have a motion platform for flight simulation. The motors are terrible though. They are windscreen wiper worm drives with loads of backlash. I’m thinking that a 3d printed strainwave motor could be the solution. It hink i’d need 2x to 3x torque though but am concerned that a stronger motor would simply result in mechanical failure probably on the toothed belt. Has anyone else tried to scale this up in torque?

[DDeGonge]

I would definitely not recommend a 3D printed gearbox for loads that high. While this gearbox could probably operate at up to a 20Nm output, I have some hesitation about the lifetime. Even at 10Nm I wouldn't be surprised to start seeing fatigue failures after a few weeks under these loads.

If you need linear motion, using a cheap ball screw with a geared down input from a motor using a belt reduction would be a reliable way to hit very high output forces. If you need rotation, an off the shelf solution would be expensive but if you want it to last any amount of time it's either that, or likely a whole lot of engineering and trials before you hit a reliable solution.