Plastic gears vs metal gears. Change up a gear!

Plastic gears vs metal gears. igus® gears offer up to 80% more wear resistance than conventional plastic.

igus® is known throughout the world for its innovation of polymers, dating back as far as the 1960’s, but until recently it has not been associated with polymer gears. This has now changed with its entry into the polymer gears market. But we get the same question from our customers “plastic gears versus metal gears? How do they compare?”

If you want to learn about how the igus® gears are manufactured:

To find out more about plastic gears vs metal gears and the clear benefits of igus® polymers, keep reading.

There are three main points to consider:

1. Plastic gears vs metal gears. Easy configuration and NMO

Plastic gears vs metal gears.

As with the majority of igus® products, we offer a free gear configurator that can create a model within 1 minute online. The beauty of this tool is you have the flexibility of picking from a range of materials, you can see the geometry of the part in 3D, and you can order an individual gear or one million, there is no minimum order quantity.

You can also download a STEP file to use in your design and a data sheet. All for free. We have always wanted to give customers the flexibility to incorporate igus® products into their designs and applications at the beginning of the process, and tools like this make it possible.

This is not something that most metal gear suppliers offer.

2. Plastic gears vs metal gears on delivery

As a society we a have become obsessed with speed. We are impatient creatures and are not organised enough, so a bit But, plastic gears vs metal gears, what can get you the quickest delivery?

Plastic gears vs metal gears delivery

Luckily, 3D printed gears can be manufactured and dispatched within 72 hours, which is ideal for those time-critical jobs!

igus® also has a large range of standard injection-moulded gears in stock, so it may be that changing from metal to plastic is not as difficult as you think. Producing plastic gears is also more cost-effective, therefore, the cost to customers of plastic gears is significantly lower than metal gears.

So, referring to the early “plastic gears versus metal gears” debate, lower cost, quick delivery…. Do you still need convincing?

3. Free plastic gear engineer support

contact an expert

Support for customers has always been essential for igus®, another reason why the configuration and service life tools are so important for us to have available. We have engineers that cover the UK, who provide a free visiting service, no matter where you are!  The engineers have an extensive working knowledge of igus® polymers and applications and if they require further support, we have product managers who will add to the knowledge bank.

Not only that, we are a subsidiary, so we have the international backing of not only our parent base in Germany, but all over the world. We have vast experience and expertise worldwide, enabling us to pool wisdom from near and far.

We offer digital consultations via email. Phone or Teams’ meetings. We also have live chat available with humans answering your questions and not robots. Can your metal gear supplier offer that?

Improve your gears now! 

Times are changing, people are more aware of their options and innovations in plastics are creating controversy when it comes to the plastic versus metal debate.

But when you can get parts quickly, you can make savings, you can download CAD files into your design for free, you can increase the lifetime of your gear and you can have support from an expert team, why would you not change from a metal gear to a plastic one?

Click here for the 3D printer service design guide          

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Conveyor solutions. Are your conveyors running on a knife edge?

Conveyor solutions and their importance are often underestimated in our world. Indirectly, conveyors keep the world moving, keep production lines running, keep breakages to a minimum and without them, the world grinds to a halt.

How to significantly increase your conveyors’ productivity

Given the importance of these conveyor solutions, we need to consider the way in which we can increase conveyors productivity. How can we make a positive impact in applications and industries? What can we do to improve systems that are working well,  and make them perform even better?

Do you want to:

  • reduce downtime?
  • increase service life?
  • save money?

In this blog, I will explain what conveyor solutions you can do this by making one small change to your application, change your metal bearings for polymer bearings.

conveyor solutions

Reduce downtime

By incorporating igus® knife edge rollers into your conveyor system, these small complete polymer rollers, manufactured from our proven polymer materials, can help prevent the conveyor from wearing. Knife edge rollers can be applied into almost every industry. They are heavily used in the food and packaging industry for the transfer of:

  • food produce and packaging containers between two conveyor platforms, especially in food sensitive environments
  • product labelling
  • warehouse product handling and transfer

By reducing wear and downtime on the machine.

Increase service life

Using igus® knife edge rollers in these environments means no contamination as they are dry running and self-lubricating. This also means that they run silently. Not requiring lubrication increases the service life of the machine or application. Dirt and dust particles do not get trapped on shafts or wearing surfaces, which allows the whole conveyor system to run smoothly. When metal runs on metal, wear is guaranteed so protecting your running services is vital to increase service life.    

igus® knife edge rollers beat conventional roller materials in every aspect. The igus® polymer materials are:

conveyor roller

Robust and can withstand high temperatures, the new A250 knife edge roller pictured can work in long term temperatures of +90 degrees and down to -40 degrees.

Dirt Resistant, the igus® materials are tested vigorously in our dedicated test lab before they are certified for use in industry.

Hygienic, many igus® materials are certified with FDA .  Corrosion-free for continued wash down cycles that withstand many chemicals.

The overall advantage of igus® polymer materials in conveyor solutions is longer lifetime and less maintenance requirements.

Would you like to learn more? Click here to read more about knife edge rollers

Save money

Taking the previous two points into consideration, it is clear to see how changing to igus® knife edge rollers can save you money, no grease is required, less maintenance, increased service life, less downtime and being polymer, they are more cost-effective to purchase. Sometimes, conventional size rollers are not required, and a custom size or shape is.

We can offer customised rollers! Custom designs are made possible from our range of 29 iglidur® materials. We can 3D print, machine, or Print to mould, all options without expensive tooling costs. Having a large range of standard rollers on the shelf, allows us to be competitive, the rollers link together to form longer bonds. However, having the ability to offer custom designs and lengths creates more opportunities to help you find a solution.

With these conveyor solutions make your conveyors more efficient and productive today!

If you have conveyors in your business, factory or part of a machine build, then please contact us for a free sample, or we can arrange for an engineer to visit you and advise on the most suitable materials for your application. Alternatively, you can read more about knife edge rollers here

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How does conventional high helix thread compare to dryspin® technology?

Did you know that igus® manufacture a type of high helix thread lead screws? And more importantly, did you know that we have our own patented lead screw technology? No? Then read on. Yes? Then you should still read on!

So, what is dryspin® technology? And what advantages does it offer compared to a conventional high helix thread?

dryspin® lead screw technology was developed and patented in 2016 by the drylin® lead screw technology development team. The goal for these lead screws was to increase service life and improve efficiency, whilst offering a configurable solution from stock.

The portfolio includes high helix lead screws made from stainless steel or aluminium. We have a variety of matching lead screw nuts made from our igus® high-performance iglidur® polymers which go towards the same goals; increase service life and improve efficiency. The drypsin® lead screws are available in pitches from 2.4mm to 100mm, and the range is ever expanding.

What advantages does it offer compared to a conventional high helix thread?

The dryspin® high helix thread geometry is an extension of conventional thread technologies such as metric and trapezoidal threads. In contrast to conventional lead screw geometries, dryspin® lead screw technology is superior due to a number of advantages:

  • Higher effectiveness
  • Low-noise and low-vibration operation
  • Longer service life due to asymmetry
  • Reduced wear
  • Higher efficiency

In contrast to a metric or trapezoidal thread, the dryspin® high helix thread has a higher pitch. This means that a small rotary movement on the screw is converted into a relatively large linear movement during one revolution of the lead screw. Efficiencies of up to 82% and a longer service life are achieved compared to conventional metal lead screw drives. Another key advantage is that thanks to igus® technologies, both lead screw and nut are dry running, enabling a clean and dry operation without dust and dirt contaminating the system and increasing wear.

Read more about dryspin® technology at igus® here.

How is the dryspin® thread different to a standard high helix thread?

dryspin vs high helix lead screws

Right: flat flank angle, dryspin® geometry
Left: steep flank angle, standard geometry

The dryspin® lead screws have a flatter flank angle than conventional high helix threads. This allows the lead screws to efficiently convert the applied force into a translatory movement. If you compared this to a steeper flank angle, the loss of force would be lower.

Left: angular toothed flanks, standard geometry
Right: round tooth angles, dryspin® geometry

Due to the rounded tooth geometry, the contact surface between the lead screw nut and the lead screw is reduced. With conventional lead screws, there is a greater contact of two surfaces moving against one another, which creates more vibration and can create a squeaking noise. The rounded teeth on the dryspin® lead screws minimise this effect and the thread moves vibration-free and virtually silently.

To conclude, the dryspin® thread is quieter, more efficient and increases service life over conventional lead screws, so change your lead screw today!

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Is plastic better than steel? Save time and money with igus®

Are plastics a viable alternative to save time and money?

Is plastic better than steel

Is plastic better than steel? I know that someone people will think that is extreme and that plastic won’t be able to withstand the same forces and impacts that metal would, but you might be surprised.

There are plastics that have been designed to be an alternative to steel components. When you consider the disadvantages of using steel, such as:

  • Corrosion/rust
  • Lubrication required
  • Expensive

So, considering these vulnerable features of using steel, it Is no wonder that people are looking at replacing steel parts with more cost-effective and environmentally friendly alternatives. So, is steel better than plastic in the long term?

Is plastic better than steel and should you replace it?

It may seem daunting but switching steel parts for plastics can offer a multitude of benefits. With igus® products the key features are:

  • 100% corrosion-free
  • Low weight
  • Vibration resistant
  • Maintenance-free
  • 100% lubrication free
  • Cost-effective

But the main key areas are they can save you time, money and help save the environment.

Save time

The above benefits are advantageous for machines and applications however they also have an added boost of reducing your downtime from component failure and regular maintenance. With smart plastics, predictive maintenance and condition monitoring ensure that unplanned downtime is a thing of the past.

Save money

Back to the question, “is plastic better than steel?” and we can consider costs. Currently the cost of steel is rising and is sitting at 20% higher than It was 18 months ago. The manufacturing of plastics is ever evolving, and new technologies are being used which are keeping the costs of producing plastic low. Linking to the above point of intelligent plastics, this reduces unplanned downtime, eliminating catastrophic failures, which are expensive. igus® mass produces parts, recycles old parts, re-granulate broken parts, all keeping costs low to produce, making plastic cost-effective.

Save the planet

igus® has a few “green” initiatives: our recycling program, the chainge program and we are also invested in Mura technology. All initiatives help to reduce the eco footprint, whilst also reducing the total cost of ownership/running cost.  Whereas most of our competitors’ products are manufactured from various grades of steel, which are costly to purchase and not environmentally friendly, the igus® energy chain is cost-effective, hard wearing and has less of an eco-footprint. This is the same for our plain bearings, 100% plastic.

You can read about what igus® is doing to help on our sustainability blog page here.

At the beginning I mentioned downtime costing industries billions of pounds every year and by changing from steel to plastic, you can reduce unplanned downtime, save time and money. So, is plastic better than steel? Not necessarily…..  

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What is the difference between multi-start threads and single-start threads?

Multi-start thread or single? There are so many confusing terminologies surrounding lead screws, so let’s strip it down and get back to basics.

What is the difference between a single and multi-start thread?

Lead screws are machine elements that convert a rotary movement into linear travel. Lead screws consist of a cylindrical round thread on which a single helix spirals the continuous length, transforming it into a screw. The threads can have, for example, the trapezoidal thread form, metric thread form or the dryspin® geometry designed by igus®. The dryspin® thread is similar in structure to a high helix thread.

Let’s have a look at what constitutes a single threads and a multi-start threads.

multi-start threads and single-start threads?

L = LEAD = Linear travel in mm per one screw revolution
P = PITCH = Spacing from one thread to the next

Single start threads

The lead screw on the left (number 1) shows a single start lead screw. You can identify this by having one single thread. This is what is referred to as a single start. This means that the distance between the flanks, marked by pitch, is also the linear travel (lead) in millimetres per revolution of the lead screw.

Multi-start threads

For lead screw number 2, a further thread has been added, which is shown with the green illustration. This means that with one revolution of the lead screw the two-fold stroke is achieved (lead = 2 x pitch). The start of the thread is offset by 180°, i.e. opposite each other. This is classed as multi-start threads, or sometimes referred to as a two-start thread.

Finally, the third lead screw in this example shows a four-start lead screw. This means we have 4 thread starts indicated by orange, green, purple and blue. For the linear travel the same calculation applies here as for the other examples.  The linear travel (lead) is therefore four times the distance between the flanks. The start of the thread is at a position of 90° to each other.

For more information about lead screws, multi-start threads and single-start threads, read more blogs here

Which thread is best for your application?

Deciding whether to use multi-start threads or single for your application is sometimes tricky, simply because there are advantages and disadvantages to both. For example, a single start trapezoidal thread will self-lock, whereas a multi-start thread will not. On the other hand, you can travel much faster with a multi-start thread.

Our experts are on hand to offer application advice, to ensure that the best possible thread choice is used in your application.

If you need further information on an of our leadscrews, please visit the website or speak to one of our experts on 01604 677240.

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3 reasons why industrial manufacturing robots are important

Industrial robots are being used more and more in so many industries, no more so than the Manufacturing industry. But why are these industrial manufacturing robots important? Also, what constitutes an industrial robot?

What is an industrial manufacturing robot?

delta robots

According to the International Federation of Robotics (IFR) the term “industrial robot” is standardised as: “an automatically controlled, reprogrammable multipurpose manipulator, programmable in three or more axes”. These can be further identified as:

For blogs on the various robots visit: and search the robot.

How can industrial robots help?

Within the manufacturing world there are various areas where robots are included in the manufacturing process. Areas such as:

The integration of robots in these areas in the manufacturing industry, allows rapid growth where perhaps such growth wasn’t possible before.

1. Warehousing with industrial manufacturing robots

 industrial manufacturing robots

Warehousing will continue to grow. In comparison, however, this will not grow as fast as other industries. This is down to a high level of industrial manufacturing robots collaboration already widespread throughout warehousing. Areas such as palletising in warehouses tend to be using industrial robots to enable larger products to be added onto pallets. With these robots, using triflex® energy chain not only protects the power cables to the robot, it also reduces downtime. Its modular design allows cables to be inserted quickly and easily, preventing expensive stoppages.

2. Manufacturing with industrial manufacturing robots

Robots are well established in the manufacturing industry where reliability is of paramount importance, as well as an understanding of the required maintenance and lifetime. Condition monitoring and predictive maintenance helps these industrial robots become even more intelligent. Using “smart plastics” the integrated sensors and components provide information and suggest required steps, such as maintenance or shutting down the system in order to prevent damage that is expensive to repair. Industrial robots are expensive bits of equipment, and breakages and downtime are expenses that can be avoided with products like the igus® smart plastics.

3. Cleanroom robots

cleanroom industrial manufacturing robots

The pandemic last year triggered a boom for sanitary robot solutions in hospitals, industrial facilities and test laboratories. As we start to come out of the pandemic, industries that invested in automated sanitation solutions will continue to do so, and predictions are that these will continue to rise.

 Cleanroom robotics minimise contamination whereas the risk of contamination with humans is greater. Automating processes in cleanrooms with products such as the igus® e-skin® energy chain, stainless steel leadscrews and stainless linear systems, allows robotics to continue to work in these harsh, pristine environments.

Industrial manufacturing robots are important as they are helping collaboratively to increase growth in areas which may be struggling. If you need help with bearings, energy chains, leadscrews or cables for your robot, visit the website:

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Bearing lubrication; 3 important reasons why you shouldn’t lubricate bearings

bearing lubrication

Bearing lubrication, a topic we wrote about last year, which you can read here: but this new blog is more lead screw specific.

A misconception when it comes to lead screws is the insistence in greasing them! Granted, some products require lubrication to ensure that they do not seize up, however, it is easy to forget that lubrication is not a prerequisite for all products. And with any igus® products it is simply not needed, so please save yourself time and money and don’t bother!

3 reasons why bearing lubrication isn’t needed with igus®

Reason 1 – Waste of money

Our lead screw systems are developed for maintenance-free and completely dry operation, meaning no bearing lubrication is required. With this in mind, you cannot really compare a lubricated lead screw system with a dry-operating system. They operate differently because of the external lubrication used.  Lubricants can cause a high maintenance effort and additional costs that are often not accounted for.

With igus® dryspin® products, the lack of lubrication required is down to the homogeneous structure of the lead screw nut material. This ensures that any wear is mostly linear, wear can be calculated given application specifics and therefore maintenance intervals can be scheduled in.

Our materials are characterised by their special specifications: their unique composition makes them extremely wear-resistant and resilient to almost any environment. Due to the self-lubricating effect, the lead screw nuts are 100% dry-running and maintenance-free. Their special composition makes them extremely wear-resistant, robust and self-lubricating. Therefore, using igus® products means no grease, saving you money.

Reason 2 – Contamination

Bearing lubrication can penetrate cavities, mix with dirt and dust particles, and bring them to the surface. Particles such as dust and fibres can adhere to conventional lead screw drives due to the grease or lubrication used. In dirty environments, this greatly decreases service life.  In comparison, when using igus® products you will increase the service life. No dust particles are able to grip to the lead screw, therefore they are ideal for both dirty and clean environments.

Cleanroom applications demand products where contamination is not acceptable, and dryspin® products are ideal for this. The above-mentioned advantages make it possible for dryspin® lead screw drives to be used in special industries, such as food and packaging, medicine or pharmaceutical technology to name just a few. These industries make it mandatory that the installed products are absolutely clean, hygienic and very easy to maintain.

Reason 3 – Bearing lubrication can decrease the life of the bearing

As a rule, our materials are resistant to certain oil-based lubricants, but the use of these lubricants could possibly affect the lead screw nut in a negative way. People will always insist on bearing lubrication as a solution and if this lubrication is not done consistently, issues arise with wear and seizing.  Having the lubrication internally within the iglidur® material allows smooth running without having to grease. This is the key to a long service life.

Ultimately, that is what you want, a long service life for your bearing, without contamination and saving money.

Need I say more…..

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6 ball bearing materials you need to know about

Ball bearing materials are are vast. It also varies depending on the ring materials. This ensures that the interplay of cage, inner ring and outer ring in the system is harmonised. But why is this important? It is essential to have the right combination of materials in the ball bearing for specific applications. Applications that involve excessive heat, applications that need to conform to specific industry standards. Ultimately, no matter what the application, the focus needs to be on ensuring that the ball bearings running properties are always cohesive.

With igus® xiros® ball bearings, we offer stainless steel and glass balls. These work in harmony with the various polymer cages and races that we manufacture, however, for other ball bearings, the options are far greater.

Below are the most common ball materials that work efficiently with various ring materials.

Balls for metal ball bearings:

Ball bearing materials – Roller bearing steel 1.3505/100Cr6

For conventional metal ball bearings, hardened steel balls are often the preferred choice. The most popular material is a chrome steel with about 1% carbon and 1.5% chrome. Martensitic chrome steel is very well-suited to ball bearing production. The properties of this material ensure stability, they are resistant and durable in continuous operation, all key elements required for these balls. This is achieved through the steel crystalline structure. Susceptibility to corrosion tends to be low and this means that cylindrical rollers and needle rollers tend to be made of this material. But lubrication is essential so there can be issues with this.

Plastic ball bearing materials

Balls for plastic ball bearings:

Stainless steel 1.4401 and 14401 (SS316L)

For ball bearings made of plastic, such as xiros® ball bearings, unhardened stainless balls are usually used. They are exceptionally corrosion-resistant and are also very resistant to saltwater and alkalis. The maximum permissible load is already restricted by the limits of the material in the plastic rings. Another reason for stainless steel balls to be used in the majority of plastic ball bearings is that they cost less than glass balls.

Soda-lime glass

Glass ball bearing materials are used when a metal-free ball bearing is needed or the requirements for chemical resistance are high. Soda-lime glass is used in bottles, drinking glasses and flat glass, as well as as a ball bearing material. It has good chemical properties, therefore, making them suitable for environments that can be exposed to brief chemical stress, but not to great thermal stress.

Ceramic ball bearing materials

Borosilicate glass

This type of glass ball bearing materials are much more expensive than soda-lime glass. Borosilicate glass is even more chemical-resistant than soda-lime glass, which means that it is used in applications involving strong acids. This material has very good resistance to heat and to changes in temperature, mechanical stability and low coefficient of linear expansion.

Balls for ceramic ball bearings:

Aluminium oxide Al2O3

Ceramic ball bearing materials are made of aluminium oxide, also known as oxide ceramics, have a polycrystalline structure. The properties of the lightweight balls include good corrosion, abrasion and heat resistance. They are extremely resistant to corrosion, however, it is important to avoid contact with hydrofluoric acid, hydrochloric acid, warm sulphuric acid and strong alkaline solutions. They are also electrically insulating. Balls made of Al2O3 aluminium oxide are white to ivory colour and are manufactured according to ASTM F 2094 Class II/III.

Silicon nitride Si3N4

Balls made of the silicon nitride ceramic material are lightweight but durable and offer resistance to corrosion. The material has an insulating effect. The balls are also self-lubricating and have great resistance to temperature fluctuations. They are much more expensive than balls made of aluminium oxide. Balls made of Si3N4 are a black mother-of-pearl colour.

To read more about the different ball bearing and ball bearing materials visit

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Solutions for successful and elegant industrial interior design

Industrial interior design is not only about aesthetics but practicality. The new trend is to try and retain original aspects of interiors within the design and people are loving the industrial vibes. Not only that, but people are being clever with their design, using all available space, no matter how limited it may be. People’s creativity is starting to show and with the help of companies like igus®, it is now being made possible without breaking the bank.

industrial interior design

Sliding drawers

With igus® drylin® linear rails, bespoke sliding units are made possible. Not only are these lubrication-free and offer a quiet operational movement, but they are low-cost and stock items. With their aluminium profiles, these systems can be used visibly or hidden. The look of the aluminium is edgy yet smooth, perfect for industrial interior design.

Interactive mirror

industrial interior design

This application is so unique and showcases brilliance in innovation. The split design houses drylin® linear rails to offer the smooth-running motion. It also is ideal for bathroom environments as drylin® rails are corrosion- free and lubrication-free. No nasty grease or oil spilling into your bathroom.

Do you have more questions about drylin® guides and rails? Read our frequently asked questions here.

This amazing high-tech design utilises the rails to split the mirror revealing a docking station for an iPhone. The device connects via the docking station and can be controlled without touching, simply through gestures. A software program decodes the gestures and transforms them into a clear algorithm. It is simply magic!

Movable kitchen furniture for industrial interior design

Today, people’s priority for the modern kitchen is to combine innovative technology with contemporary design. Key benefits for kitchens are that movements should be: easy and quiet, durable and resistant products utilised throughout, and all elements must be 100% lubrication and maintenance-free. igus® products deliver on all counts. Within kitchens, sliding drawers, soft closing doors, movable units, all creating space and storage but cleverly using off-the-shelf products to keep costs low.

Most interiors, industrial or not, can use igus® products. Perhaps not visually, but fundamentally the properties that are the foundation of igus® products means that these are ideally suited for industrial interior design applications.

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How to make machine guard doors move with ease

When you think of large machine guard doors you might imagine the dirt, the dust & swarf, the noise. However, there are products designed for these large industrial machines which can help prevent noise, reduce friction and are resistant to dirt.

So how can you reduce these issues? Lubrication? Fortunately, there are products available which not only eliminate the issues but can do so without the addition of lubrication. For more information on other igus® products which do not require lubrication please read this blog

sliding machine guard doors with ease

Interrupted sliding on machine guard doors

Traditionally, industrial machine guard doors tend to have conventional metal ball bearing systems or steel rollers. This can be problematic with seizing, stiffness, noise and juddering movement.  The main function of a machine guard door is to open and close in a single smooth movement. The doors are there to protect the operator and if they are not easy to open and close, this can cause issues.

This is when using the new igus® hybrid roller bearings becomes extremely beneficial.  These unique bearings combine lubrication-free plain bearings with specially designed maintenance-free rollers. The technology lends itself to applications such as machine guard doors and moveable control panels, thanks to its smooth consistent operation which requires no grease or lubrication of any kind. Using igus® hybrid rollers also means low friction and with the combination of sliding liners and rollers, ensures that the load is absorbed evenly, creating a smooth gliding motion.

How does the technology work?

machine guard doors

The sliding element of the hybrid bearings enables a silent consistent movement, and combined with the integrated rollers, these bearings have low inertia and therefore low driving force and can absorb lateral forces where required.

The hybrid carriage with specially designed profile rollers combined with iglidur® polymer liners, infuses the two technologies together creating a silent smooth-running, load bearing product.

The additional liners installed in the carriage give the hybrid roller bearings a constant stable feel, weight is transmitted to the shaft more evenly. This extends the service life of shaft and rollers and allows greater maximum loads.

Other areas where these hybrid bearings can work

Designed for applications such as industrial machine guard doors, this doesn’t restrict them to just large commercial applications. They can be used for domestic applications too, such as shower doors. These bearings help misalignment which can be problematic for smaller doors, however, due to the dry-running element of all igus® bearings, these are ideal for domestic use as well as commercial and industrial use.

If you need any more information on these hybrid bearings please contact Lee Wilkins or visit the website

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