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FEATURE MATERIALS IN DESIGN & PROTOTYPING


55thanniversary motion plastics: over 6


As Design Solutions marks 55 years of covering engineering innovation, it’s worth reflecting on another quiet revolution: igus


motion plastics. What began in a small Cologne garage in 1964 has grown into a material technology that now underpins automation, robotics, medical devices, and countless industrial applications


I


n the 1960s and 70s, polymers were still viewed as second best. Metals dominated machine design, and plastics were often


dismissed as cheap substitutes. Yet Gunter Blase, founder of igus, saw untapped potential in materials engineered specifically for motion. Early breakthroughs included: • Polymer bearings that resisted corrosion and ran without lubrication


• Cable management systems that replaced heavy steel chains


• Tribologically optimised materials designed to reduce friction and wear. For industries battling contamination,


downtime, and maintenance costs, these lighter, cleaner components offered a practical alternative to traditional designs.


automation takes off By the 1980s and 90s, automation was reshaping factories. Robots, CNC machines and high speed equipment demanded reliable cable


movement and low maintenance bearings. Modular energy chains and dry running bearing materials became essential rather than experimental, supporting cleaner production lines and more predictable machine behaviour.


Digital tools anD rapiD innovation As CAD, simulation, and digital testing matured, material development accelerated. New tribopolymers were released annually, each tailored for specific loads, speeds, or environments. Key advances included: • iglidur bearing materials for automotive, medical, and industrial systems


• chainflex cables tested for millions of cycles, with a four-year guarantee


• Lightweight robotic components that helped shape early low cost automation. Behind the scenes, one of the world’s largest


test labs belongs to igus, based in Cologne. This now runs over 15,000 tests a year, a reminder that incremental improvements often come from ongoing work rather than dramatic reinvention.


Where it all started: Gunter


Blase, founder of igus, at the


Cologne garage 2 DesiGn sOLUtiOns 1971-2026 JULY/AUGUST 2026 8


sustainability, Digital engineering, anD accessible robotics The latest chapter in motion plastics is driven by sustainability and smarter engineering. The igus chainge programme turns worn energy chains into new materials, supporting the circular economy. A newly introduced PTFE-free and PFAS-tested


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