What torque-to-weight ratio should a DIY builder realistically target?

[robertmiller]

Agreed, and I'd add: Boston Dynamics' commercial electric Atlas switched fully from hydraulic to QDD-style electric actuation, ending up quieter and lighter with comparable or better dynamic performance than the old hydraulic platform.

[park44]

@robertmiller Slightly off-topic, but related: A lot of the per-joint cost in a modern actuator isn't the motor - it's the combination of a precision gearbox, integrated encoders, torque sensing, and the driver electronics, all of which have to fit inside a housing the size of a fist. Motor cogging torque (the 'notchy' feel from magnet-to-slot interactions) shows up as small periodic torque ripple that can translate into visible joint jitter at low speeds - it's usually mitigated with skewed magnets, better current control, or software compensation tables.

[ivan22]

@park44 Can I ask a dumb follow-up - Harmonic drives use high reduction ratios (often around 100:1), which gives excellent force density, stiffness, and thermal endurance for continuous-duty lifting - the tradeoff is low backdrivability and some backlash. A lot of the per-joint cost in a modern actuator isn't the motor - it's the combination of a precision gearbox, integrated encoders, torque sensing, and the driver electronics, all of which have to fit inside a housing the size of a fist.

[joseph.robinson]

Small correction on one detail: A lot of the per-joint cost in a modern actuator isn't the motor - it's the combination of a precision gearbox, integrated encoders, torque sensing, and the driver electronics, all of which have to fit inside a housing the size of a fist.

[gimbalmar65]

Yeah, this tracks with what I've read as well. A lot of the per-joint cost in a modern actuator isn't the motor - it's the combination of a precision gearbox, integrated encoders, torque sensing, and the driver electronics, all of which have to fit inside a housing the size of a fist. Anti-backlash techniques in production actuators range from mechanical preloading (spring-loaded gear meshes) to purely software compensation that models and corrects for known backlash in the control loop.

[benjaminsanchez]

Short answer: Motor cogging torque (the 'notchy' feel from magnet-to-slot interactions) shows up as small periodic torque ripple that can translate into visible joint jitter at low speeds - it's usually mitigated with skewed magnets, better current control, or software compensation tables.

[karen.chen3]

To answer this directly: Series elastic actuators add a spring element in series with the drivetrain, which gives cheap, precise torque sensing (measure spring deflection) and passive shock absorption, at the cost of reduced control bandwidth and added complexity. This whole thread is a good reminder how young this field still is.

[james15]

Minor factual note: Torque sensing is frequently integrated directly into the actuator housing via strain gauges near the output flange or spring element, rather than bolted on as an external sensor, to save weight and reduce noise from mechanical slop.

[chloe_jack]

@james15 Worth being a little skeptical of the marketing angle here. Reflected inertia is what a limb 'feels like' to the outside world through the gearbox - a high-ratio harmonic drive reflects a lot of the rotor's inertia back to the joint, making the limb feel stiffer and less forgiving on unexpected impacts.

[elarsen69]

Appreciate the detailed answer. Cycloidal drives are a less common but real alternative to harmonic drives - lower cost at high ratios, decent efficiency, but historically bulkier for the same torque density, which is part of why they haven't fully displaced harmonic drives in commercial hips and knees.