New low-cost igus carriage for curved rail made of recycled high-performance plastic

December 1, 2023 12:54 pm

Injection-moulded from re-granulated high-performance plastic, the new polymer carriages from the igus drylin econ series are highly cost-effective and sustainable, simplifying adjustment and positioning tasks. They cost less than 20% of their milled aluminium counterparts. Due to movable bearings, they can also handle cornering on curved aluminium rails without any problems.

Positioning a moving monitor for advertising in a shoe store or adjusting a gripper that transports sweets in a snack vending machine often leads to using linear guides based on recirculating ball bearings operating on carriages and rails made of steel. However, these systems are frequently oversized, and design engineers end up paying for unnecessary mechanical specifications. In times of multiple crises, ranging from rising energy costs to disrupted supply chains and inflation, many companies find cutting costs more crucial than ever. “We have therefore added a new, very cost-effective entry-level series called drylin econ to our linear guide product range,” says Michael Hornung, Product Manager for drylin Linear and Drive Technology at igus. “It’s ideal for simple adjustment and positioning tasks – including cornering.”

Costs for linear carriages reduced by around 80 percent
The new drylin econ series is a low-cost alternative to the previous linear guide in the igus drylin series. The secret to cost reduction is that the carriages are not milled from steel or aluminium but are injection-moulded from high-performance plastic. “This less time-consuming high-volume production in one casting reduces costs for a 0630-size linear carriage from €112 to 21, so design engineers save more than 80%,” says Hornung. And drylin econ operation is also economical since no maintenance is required. This is because microscopic solid lubricants are integrated into the high-performance plastic of the bushings over which the carriage moves on the rail. Unlike classic rolling bearings, they allow dry operation with no additional lubrication work. Therefore, users reduce maintenance time and material costs. These advantages make products that use the linear guide more economical and attractive. Last but not least, the system is exceptionally light. “drylin econ uses plastic and aluminium, so it is suitable for many lightweight constructions,” says Hornung.

Carriage leans elegantly into curves on moving spherical balls
drylin econ even allows movement around bends. igus produces straight and curved versions of the anodised aluminium linear rails, allowing convex and concave curved guides and movement in quarter, half and full circles. The polymer bearings for the carriage for curved rail adapt to the rail geometry with moving spherical balls. “Even during cornering, movement is smooth, quiet and rattle-free,” says Hornung. “This is especially important for vending machines, such as beverage machines in a hotel lobby, that are set up in public and intended to work as inconspicuously as possible.”

Carriages made of injection-moulding production waste
However, the new carriages from the drylin econ series are economical to operate, low-cost, and sustainable. For injection moulding, igus uses a regranulate called iglidur ECO P, made entirely of injection-moulding production waste, including sprue and defective parts. “Recycling keeps the plastic from being burned,” says Hornung. “Instead, we regranulate it and feed it into the resource-saving, environmentally friendly circular economy.”