Igus

The first product created by igus came from an enquiry from Pierburg, where the most complicated part in the enquiry was a valve cone in a carburettor. In 1965, nobody would have thought of using plastic as an alternative for a metal component, especially when using an injection-moulding machine. However, Günter Blase worked in his garage experimenting until he created the first plastic valve cone and received his very first customer. The first energy chain made of polymers was created in 1971. It was developed from a concept by textile manufacturer Schlafhorst, who came to Günter Blase as they wanted to protect cables on long travels in the tough textile factories. The double garage where these products were invented soon became too small for the future work Günter would face. Therefore, he searched to find a new site for igus, and this was found in an industrial area within Lochermule, Germany in 1977. A few years later, in 1979, igus had created a number of high-quality energy chain variants and the first igus e-chain catalogue was designed and printed.

In the same year Günter's son, Frank Blase, split the cable-carrier systems and injection moulded polymer bearings into two product groups at igus and the first plain bearing material was created, iglidur G. This material has properties which enable it to be lubrication and maintenance free, making it very versatile. Günter is known for his probing mindset and evolving spirit, so the iglidur G material was assured to be a great invention; it is still part of igus' product range today. It is known as "the classic all-rounder". Two years later, after Frank had officially joined igus, he saw an opportunity where igus could succeed faster and on a global scale. It was decided that a branch should open in the United States of America. Therefore, in Rhode Island, igus Inc was established and Carsten Blase, Frank's younger brother, took control of the branch. During the process of creating the USA facility, the iglidur X and iglidur M250 materials were created and were assigned the necessary dimensions in inches for the US market.

igus believes that customers are the centrepoint of the company's existence, they call the customers the "sun". Frank created the igus "solar system" in 1986, which is still used within igus to date. The concept is that the customer is the sun, therefore the source of energy. All employees, including team leaders, managers and directors are working together within a system, orbiting the sun. This system ensures that every employee is equal and everyone has an important role in satisfying the customer's requirements.

In the same year, the R68 energy tube was released. It was developed to provide a cable-friendly system to the woodworking and material transportation industry. It made installation easy and provided the best protection for cables in rough environments due to the enclosed design. The success of this e-chain made it inevitable that suitable cables became a focus of attention. Customers would often tell Frank that cable quality was poor and lead to complications such as corkscrew effects, core rupture and loop formation in situations of high speeds, acceleration, and large number of cycles. These conversations led to the beginning of igus' production of tribologically optimised cables, the first one being CF1, in 1989. In 1991, the first e-chain expert was programmed and published on CD-ROM, which suggested the correct configuration and offered several forms of interior separation, as well as igus’ first electronic catalogue published in 1991.

1993 marked the launch of two new product ranges. igus launched the readychain product range, a harnessed energy chain containing the desired cables and connectors. This "plug and play" system means quick and easy installation immediately after purchase. The very first shaft guide, drylin R was manufactured by igus on the back of customers asking for linear motion solutions. They were looking for a quieter and lubrication-free movements that contained all the benefits that were already known about the iglidur materials. Ordering from igus was also made a lot easier that year, as the customer would only have to place one order for the different components.

Following the introduction of drylin R, in 1994 igus introduced igubal self-aligning bearings. It was also the year that, due to the growth, a relocation was needed as the factory once again, became too small. There was not enough space for production or staff, so igus moved to Porz-Lind in Cologne, Germany as a permanent solution. They considered that they will probably need space to extend even further in the future, therefore the design of this building ensured that extensions were possible. The design of this building was carefully created by British architect Sir Nicholas Grimshaw; it includes the iconic bright yellow pylons and an open-plan design where the panels, windows, doors and loading bays were created to be fully interchangeable and make it easier to alter the headquarters when extensions are required, at a significantly lower cost.

China's subsidiary was established in 1999. This was decided from the increasing market in China for igus and the demand of energy chains, cables and bearings.

igus brought out their first triflex robotics energy chain, designed specifically for industrial robots, due to their allowance of large radius movement, in 2003. These energy chains are able to cope with torsion and round-the-clock operation. The drylin W profile rails were another product to be introduced to the igus product range that year, the start of the extensive modular system of linear guides. One further bearing range surfaced in 2008, the xiros ball bearing. They were created as an alternative for a metal ball bearing as they weigh less, are more hygienic and are lubrication-free with very low friction. These characteristics meant they are suitable for a vast range of applications.

Further changes to the factory occurred in 2009, the headquarters factory in Cologne had a huge extension. The size of the factory was increased by 60% to make room for the production of more products. This included robolink in 2009, bar stock in 2010, drylin E linear axes in 2011, 3D printing service and the introduction of smart plastics, both in 2016.

In 2019, a platform for users and suppliers of low-cost robotics components was launched, RBTX lean robotix. The igus low-cost robotic parts are matched to the users requirement for the most accurate solution, and the platform gives suppliers an opportunity to showcase their products in a new marketplace.

The most recent milestone for igus was the introduction of custom injection-moulded plain bearings that are delivered within seven days. This came into play in 2021, known as the FastLine Service. Due to the high demand of customised parts required quickly when they typically take several weeks to produce, igus decided to produce and supply customised lubrication-free plastic bearings within a few days whilst remaining cost-effective.

igus has a strong focus on sustainability, they invest into changes within the company to help fight climate change. As a company that produces high-performance polymers which can contribute to the environment and resources, they ensure they focus on being as environmentally friendly as they can as a company. One goal igus is striving towards is to be completely CO2 neutral, including their buildings and production of products.

Currently, the environmental processes igus have established are:

1. Service life: igus products are designed to be resistant to wear and are insensitive to corrosion, dirt and grease. These qualities result in the products lasting longer, so they need to be replaced less frequently, therefore less waste will be contributed to the environment.
2. Lightweight: As plastic is significantly lighter than steel, the energy required to transport igus products is reduced. Therefore, igus polymers reduce fuel consumption during transportation compared to metal.
3. Energy Saving: igus polymers have low friction and are tribologically optimised. Therefore, along with the lower weight, uses less drive energy is used to move machine parts.
4. Predictive maintenance: igus has a "smart plastics" product range. The sensors on the smart plastic components indicate any wear and tear and allow for products to be replaced before the product reaches the end of its life cycle. This ensures products are not being wasted and less components are being used to later be disposed of, contributing towards a more positive environmental impact.
5. Replaceable parts: Entire systems within applications do not have to be replaced when wear occurs with certain igus products. Instead, the part that is showing signs of wear is the only part that may need to be replaced.
6. Biopolymers: igus have developed a bearing, iglidur N54, where 54% of the material is manufactured from biological raw materials; this is another step closer to becoming more environmentally friendly.
7. Lubrication-free- igus products have solid lubricants incorporated within the polymer itself, therefore no external lubricants are used that can contribute to contamination of the environment.

Another key process, the "Chainge" program, was established in 2019 to recycle energy chains that had reached the end of their service life. The used energy chains, manufactured by igus or other manufacturers, can be sent back to igus in return for a voucher to spend on future igus products. igus reuses the material in various ways through recycling partners.

Another environmental factor igus is contributing towards is the 'HydroPRS.' igus have invested $5 million in Mura Technology Ltd, based in the north of England, who use a technology known as Hydro Plastic Recycling Solution to convert mixed plastic waste into crude oil within 20 minutes.

The organisation has a substantial focus on sustainability worldwide and igus UK have developed processes of their own. In 2021, leading on from the global 'Chainge' program, igus UK expanded this program by turning the used energy chains into plastic boards. Once the disused energy chains arrive at igus UK, they are sent to MyGroup, who turn the energy chains into the "storm boards" through shredding, granulating, blending and compressing with high temperatures. These boards are then used by igus within their product display stands that are given to customers.[3][1]

Another scheme in place at igus UK is the chainflex cable recycling program.[4] As an ISO:14001 certified corporation, igus are responsible for recycling their waste to avoid contributing to pollution. They collaborate with their recycling partner to guarantee 100% 'zero-to-landfill' recycling of their electrical cables. The revenue generated from this initiative is currently invested into the planting, nurturing and ongoing care and protection of new tree's, registered with this lead.

igus UK began the 'spring clean' litter picking process around the Northampton in June 2021 and have been out regularly since. All office waste is also recycled; nothing goes to landfill.

igus Singapore Pte Ltd was established in 1997 and is the HQ office for the ASEAN region. Its geographical coverage includes Singapore, Malaysia, Thailand, Indonesia, Vietnam and the Philippines.

igus Malaysia Sdn Bhd commenced local operations in year 2008.

igus Vietnam Company Limited commenced local operations in year 2013.

PT. igus Indonesia commenced local operations in September 2013.

igus Thailand Co., Ltd commenced local operations in year 2013.