Innovation meets sustainability: Save costs with motion plastics for the industry and automation of tomorrow

From the energy chain series made from recycled materials to PTFE-free materials: At Hannover Messe 2025, igus will demonstrate how customers can save with sustainable motion plastics solutions. (Source: igus GmbH)

Amid the currently challenging economic environment, igus is sending a positive signal for innovation and sustainability. For Hannover Messe 2025, the motion plastics specialist will present its latest product developments, demonstrating the innovative strength "made in Germany". From PTFE-free materials to a complete series of energy chains made from recycled material, and a new dry cleanroom certificate for igus e-chains developed in collaboration with Fraunhofer IPA.

In a time when global markets are characterized by uncertainties and political tensions are increasing, companies face various challenges. More and more customers need to save costs. But sustainability is also becoming an increasing pressure for companies. "The way we live and work is constantly changing. Therefore, we always see the changing framework conditions as opportunities," emphasizes Tobias Vogel, Managing Director of Plain Bearing and Linear Technology at igus. "They motivate us to explore new paths and develop innovative solutions for our customers." Michael Blass, Managing Director of e-chain systems at igus, adds: "We want to offer them innovations 'made in Germany' that strengthen their competitiveness and at the same time demonstrate sustainable solutions that provide real benefits – without sacrificing quality or incurring high costs." Both machine manufacturers and operators benefit twice from the advantages of solutions made from high-performance plastics. At the same time, they require no lubricating oil or grease, which also protects the environment and reduces costs and maintenance effort.

PTFE farewell: igus is replacing all standard sliding bearing materials

A sustainability challenge that will affect many companies is the upcoming decision regarding the use of polytetrafluoroethylene (PTFE). Regardless of whether a ban will be introduced, igus has been researching alternatives to PTFE for several years. "We are developing new formulations, conducting extensive tests, also checking our materials for PFAS compounds, and adapting our manufacturing processes to continue offering suitable solutions to our customers in the future," says Tobias Vogel. Now, igus is expanding its product range to include all iglidur standard materials as PTFE-free variants. These include materials such as iglidur J, W300, M250, G, X, and H. In other product areas like linear guides, turntable bearings, or sliding films, igus already offers PTFE-free and PFAS-tested alternatives. Tests conducted in the company's own test laboratory on friction and wear behavior also show significantly better performance of the materials with substituted PTFE compared to the PTFE-containing reference. The research into alternatives has thus provided clear added value.

80 percent CO2 savings: From old energy chains and fishing nets to recycled e-chain series

Following the successful development of the first energy chain made from recycled material in 2022, igus is now replacing the entire catalog of the standard energy chain series E2.1 with the new recycled material igumid CG LW. This is produced from old energy chains recycled through its own "chainge" program, 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 Michael Blass. "Furthermore, it is proof that sustainability does not necessarily mean higher costs. The recycled E2.1 series will be available at the same price as the previous standard material energy chains." But that's not all: it also has identical mechanical properties and an 80 percent lower carbon footprint compared to the standard material energy chain series.

From dry cleanroom to land power: New technologies for tomorrow's industry

In addition to a sustainable future for technical plastics, igus is also advancing the development of innovative solutions and certifications for specific application areas – for example, the dry cleanroom for battery manufacturing. This is becoming increasingly important given the rising demand for lithium-ion batteries for the growing electric vehicle market – but also brings demanding production environments. "In the dry cleanroom for battery manufacturing, many systems fail quickly and need to be replaced after two to three months," explains Michael Blass. Two years ago, igus introduced the E6.29, the first certified energy chain for the dry cleanroom. Now, the company has developed a new certificate together with Fraunhofer IPA that confirms the cleanroom suitability of igus e-chains in long-term testing. For example, the e-skin soft SKS28 still achieved ISO Class 4 after 15 million double strokes or 10 months – the best possible result. The E6 also proved its durability in long-term testing, 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 researching and developing in many other forward-looking areas, demonstrating that there is still significant innovation potential in German industry – from low-cost automation solutions like FTS for intralogistics to the world's first mobile land power connection system for container ships.