Forged Aluminum PTO Handles for Higher Strength and Truck System Reliability

About the Case

Application: Commercial Vehicles
Product: Power Take-Off (PTO) Auxiliary Drive System Product: PTO Handle Component
Material: Aluminum Alloy
Capabilities: Aluminum Forging, DFM Optimization, CNC Machining

Why Teamsworld

• Customer Challenges:

  A commercial truck manufacturer needed to improve the reliability and durability of a PTO (Power Take-Off) handle for auxiliary drive systems. The original aluminum die-cast handle allowed multi-part assembly but was reaching its strength and fatigue limits under high-torque operation. The customer aimed for a one-piece, forged design to enhance structural integrity and reduce assembly complexity. Key challenges included managing the increased weight from higher-density forged aluminum while ensuring torque transmission, ergonomic handling, and compatibility with existing bearing and mounting interfaces.

• Capabilities Leveraged:

  Teamsworld provided comprehensive DFM guidance to transition from die casting to forging. We selected high-strength aluminum alloy 6061-T6 for optimal strength-to-weight performance. Engineering analysis optimized cross-sectional geometry to reduce weight while maintaining torsional rigidity, and reinforced critical load areas for torque and bearing integration. Advanced forging techniques combined with precision CNC machining ensured dimensional accuracy, consistent material density, and reliable one-piece construction. The solution balanced structural performance, ergonomics, and manufacturability for scalable mass production.

• Results:

  The forged aluminum PTO handle achieved significantly higher strength and fatigue resistance compared to the original die-cast design. One-piece construction reduced assembly complexity and improved torque transmission reliability. Optimized geometry minimized weight increase, preserving handling ergonomics. The upgraded handle enhanced overall PTO system performance, durability, and safety, and has become a standardized design for future truck models, supporting long-term reliability and supply chain scalability.