Saving costs with motion plastics for the industry and automation of tomorrow.
igus is showcasing PTFE-free materials and a complete energy chain series made from recycled materials for a sustainable industry at the Hannover Messe In the midst of the current difficult economic situation, igus is setting a positive example for innovation and sustainability. At Hannover Messe 2025, the motion plastics specialist will be presenting its latest product developments, which will demonstrate innovative power “made in Germany”: PTFE-free materials, a complete energy chain series made from recycled materials and the new dry cleanroom certificate for igus e-chains, which was developed together with the Fraunhofer IPA.
At a time when global markets are characterised by uncertainty and political tensions are increasing, companies are facing various challenges. More and more customers have to save money. Companies are also under increasing pressure to act in terms of sustainability. “The way we live and work is constantly changing. That’s why we always see varying conditions as opportunities,” emphasises Tobias Vogel, CEO Plain Bearing and Linear Technology at igus. “They are an incentive for us to break new ground and develop innovative solutions for our customers.” Michael Blass, CEO E-Chain Systems at igus, adds: “We want to offer them new products ‘made in Germany’ that strengthen their competitiveness. We also want to find sustainable solutions that provide real benefits – without compromising on quality or incurring high costs.” Both machine manufacturers and operators therefore benefit twice over from solutions made from high-performance plastic. At the same time, they do not need any lubricating oil or grease, which protects the environment and reduces costs and maintenance work.
Goodbye PTFE: igus changes all standard plain bearing materials
One challenge sustainability poses that will affect many companies is the upcoming decisions regarding the use of polytetrafluoroethylene (PTFE).
Regardless of whether there will be a ban, igus has been researching alternatives to PTFE for several years. “We are developing new formulations, carrying out extensive tests, checking our materials for PFAS compounds and adapting our production processes so that we can continue to offer our customers a suitable solution in the future,” says Vogel. Now igus is expanding its product range to include PTFE-free versions of all iglidur standard materials. These comprise the materials iglidur J, W300, M250, G, X and H. igus already offers PTFE-free and PFAS-tested alternatives in other product areas such as linear guides, slewing ring bearings and tribo-tape liners. Analyses in the in-house test laboratory regarding friction and wear behaviour also show a significantly better performance of the materials with substituted PTFE compared to the reference containing PTFE. Research into alternatives has therefore generated significant added value.
Saving 80% CO2: from old energy chains and fishing nets to a recycled e-chains series
Following the successful development of the first energy chain made from recycled material in 2022, igus is now converting the entire catalogue range of the standard energy chain series E2.1 to the new recycled material igumid CG LW. This is made from old energy chains that are recycled via the company’s own “Chainge” programme, as well as old fishing nets. “With this recycled chain series, we enable customers to contribute to the circular economy for plastics together with us,” says Blass. “It is also our proof that sustainability does not have to be expensive. The recycled E2.1 series will be available at the same price as the previous e-chains made from standard material.” That’s not all, though: it also has identical mechanical specifications and an 80% lower CO2 footprint compared to the energy chain series made from standard material.
From dry cleanrooms to shore power: new technologies for the industry of tomorrow
In addition to a sustainable future for technical plastics, igus is also driving forward the development of innovative solutions and certifications for special areas of application, e.g. the dry cleanroom for battery production. As the market for electric cars and hence the demand for lithium-ion batteries continues to grow, this is becoming more and more important. However, it also requires demanding production environments. “In the dry cleanroom for battery production, many systems break down quickly and have to be replaced after two to three months,” so Blass. Two years ago, igus presented the E6.29, the first certified energy chain for the dry cleanroom. Together with the Fraunhofer IPA, the company has now developed a new type of certificate that confirms the cleanroom suitability of igus e-chains in long-term tests. Even after 15 million double strokes or 10 months, the e-skin soft SKS28 still achieved ISO Class 4 – and therefore the best possible result. The E6 also proved its worth in the long-term test and was only downgraded from ISO Class 4 to 5. This makes igus one of the pioneers in this field. At the same time, the company is conducting research and development work in many other forward-looking areas, demonstrating that there is still plenty of potential for innovation in German industry. From Low Cost Automation solutions such as AGVs for material handling to the world’s first travelling shore power connection system for container ships.
Visit them at Hannover Messe 2025 in Hall 6 at Trade Show Stand E26!
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