The trochoidal-gear technology has been growing in groundbreaking fields. Forthcoming applications are demanding to this technology a step forward in the conceiving stage of positive displacement machines. The compendium of the qualities and the inherent characteristics of trochoidal-gear technology, especially towards the gerotor pump, together with scale/size factor and magnetic-driven transmission has led to the idea of a magnet-sleeve-sealed variable flow mini trochoidal-gear pump. From its original concept, to the last phase of the design development, the proof of concept, this new product will intend to overcome problems such as noise, vibration, maintenance, materials, and dimensions. The paper aims to show the technological path followed from the concept, design, and model, to the manufacture of the first prototype, where the theoretical and numerical approaches are not always directly reflected in the prototype performance results. Early in the design process, from a standard-commercial sintered metal mini trochoidal-gear unit, fundamental characteristics and dimensional limitations have been evaluated becoming the strategic parameters that led to its configuration. The main technical challenge to confront is being sealed with non-exterior driveshaft, ensuring that the whole interior is filled and wetted with working fluid and helping the hydrodynamic film formation, the pumping effect, and the heat dissipation. Subsequently, the mini pump architecture, embodiment, methodology, materials, and manufacture are presented. The trend of applications of polymer composite materials and their benefits wanted to be examined with this new mini pump prototype, and a pure polyoxymethylene mini trochoidal-gear set has been designed and manufactured. Finally, both the sintered and the polymer trochoidal-gear units have been experimentally tested in an in-house full-instrumented mini test bench. Although the main goal of the presented work is the development of a new mini trochoidal-gear pump prototype rather than a numerical study, the results have been compared with numerical simulation. Subsequently, the prototype of the mini trochoidal-gear pump is a feasible proof of concept supported by functional indexes and the experimental results.
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