Customer application examples

For repair of the roof-mounted water cannons of airport fire-extinguishing vehicles, the maintenance technicians of Fraport AG found cost-effective replacement parts in the form of printed gears made of iglidur i3 that satisfied the high load-capacity requirements.

Standby GmbH needed suitable, durable gears for the small stepper motor of its newly developed searchlight for emergency vehicles. The wear-resistant 3D-printed gears made of iglidur® i3 were best suited for this.

The high concentration of the protein troponin in the blood is an indicator of a possible heart attack. For accurate measurement, the rotor of the stepper motor in the measuring device must achieve an angular displacement of less than 0.1 degrees. The 3D-printed gears made of iglidur® i3 play the decisive role here.

3D-printed clamps made of iglidur® i151 ensure the precise swivelling of a microscope camera, which provides the real-time diagram of the printing process of electrical microcomponents.

With a 3D-printed gear wheel, the tolerances could be improved and a smooth "levitation" guaranteed.

Modern DIY motion simulators are accompanied by loud operating noises. How can the 3D-printed igus® sliding components significantly reduce the mechanical noise in the simulator? Find out more in the following use case.

With igumid® P190, a special connection element could be manufactured for the igus® energy chain, which enables a more compact design of the large-capacity 3D printer and thus saves space and money.

A device was made from iglidur® i190 in 3D printing so that drylin® rails lie at right angles on the work surface of a profile saw. An optimal solution for precise cutting for large orders.

The complex special glider was urgently needed on the construction site in the Thyssenkrupp test tower. The igus® 3D printing service was able to deliver it within 48 hours.

A complex bevel gear was required for the drive unit of a dosing unit. Due to the small installation space of the dosing unit, only 3D-printed components could be considered, as these were able to fulfil the complex geometry and requirements.

To allow long exposures in astrophotography, a device with a gear and motor was developed to counteract the Earth's rotation. The gear made of iglidur i150 ensures precision and stability.

Light, delicate and resistant - the Technical University of Zurich (ETHZ) relies on finger joints made of iglidur® i6 for the rapid production of customised hand exoskeletons.

With igus® components, an ejection mechanism has been developed that helps to collect real data on the movement and position of objects in space and thus to remove space debris.

The steering system of the 3D-printed vehicle had too much clearance and quickly became inaccurate. Ball bearings made of the iglidur i150 tribo-filament ensured precise, stable device rotation.

"The 3D-printed component made of iglidur® impressed us with its quality, stability, strength, dimensional accuracy and the running properties between the crossbeam and spindle." Project team of the Ansbach mechanical engineering school.

In order to ensure the lightest and most durable adjustment of an innovative rear spoiler, components made of tribologically optimised iglidur® plastic are used at the bearing points of the wing, so that low-friction and maintenance-free adjustment can be achieved.

A plain bearing broke in a WAREMA Sonnenschutztechnik GmbH moving rack, causing a delay in production. 3D printed prototypes made of iglidur i3 facilitated a new split plain bearing design that allowed faster replacement.

To make the igus® energy chain more durable, adapter clips were developed for the transition between the glide shoe and chain. Together with the 3D printing team, the adapters were printed from iglidur® i6 and tested. Conclusion: "Comparable to injection moulding."

Thanks to the tribologically optimised iglidur i150 filament, components in the movement that are exposed to particularly high mechanical stress were able to achieve a significantly longer service life and a more regular escapement rate than parts made of conventional PLA.

A classical grand piano has been fitted with new iglidur® i3 touch hammers. Pianists who have tested it say "it's like switching from an Austin Seven to a Ferrari."

"It's running like clockwork again - only better!" The broken gear from a tractor used by igus® was reconstructed and printed within a few hours.

Replacing the regular plastic plain bearing with a 3D printed model made of iglidur i3 means that the pram no longer has to be lubricated and now runs very smoothly.

Because the manufacturer was unable to supply spare parts for his e-bike's gearbox, the customer had igus print gears made of iglidur i3. The result is improved performance and complete satisfaction.

Even after more than 2000 miles of use in a classic car, the customer could not detect any wear on the rebuilt intermediate shaft with gears made of iglidur® i6.

Robust sprockets with special dimensions delivered in less than 72 hours. iglidur® i6 in use in a racing car as a chain tensioner in the chain drive.

"High flexibility and fast delivery times are crucial when building prototypes - it is precisely this specification that we appreciate about the possibility of quickly selecting and printing a large number of variants via the online configurator at igus® gear." Easelink founder Hermann Stockinger.

50% cost reduction, delivery within a few days, improved sliding properties and longer service life. The spare part made of iglidur® i3 improves the machine and reduces costs at Conti Tech hose GmbH.

The cost-effective and fast manufacture of small volumes of abrasion-resistant special parts persuaded the company Kempf to use sliding elements made of iglidur i3 in its 'Darios' accelerator ring.

Replacement parts made of iglidur i180 are 15 times more cost-effective than the special metal sliders previously used by the customer and can be delivered within a few days.

The standard metal sprocket produced high running noises. After two months in use on two wheels, the replacement part made of iglidur® i3 has significantly minimised the background noise.

By switching the gripper production from aluminium to 3D printing with iglidur® plastic, Carecos Kosmetik GmbH was able to save up to 85 % of the costs and 70 % of the production time.

For a fully automated drive-in Corona testing station, a robot arm gripper was made of iglidur i3 with laser sintering. This reduces the load on medical staff.

Within a few hours, a much-needed replacement bearing for a camera trolley was printed and handed over to the happy customer.

A customer needed a new rudder bearing for his sailing boat. His conclusion: "For me, this is a perfect example of how Industry 4.0 works. From the task definition to the real solution of a highly customised design task, it only took 3 weeks and only 2 hours on the computer."