smart plastics MWS: individual real-time monitoring has never been easier

The smart plastics "mini wear sensor" (MWS) is used to record the percentage of abrasion on moving system parts in order to avoid possible operational failures at an early stage.

smart plastics mini wear sensor (MWS) The smart plastics MWS can be used in a wide variety of application areas.
With the smart plastics mini wear sensor you can monitor the wear status of your abrasion-stressed system parts in real time. The system consists of robust, 3mm x 4mm sensors that can easily be glued or screwed into the material to be monitored. The sensor continuously measures the condition of the material and sends a signal when the value falls below a critical level. This allows you to carry out condition-based maintenance and avoid unnecessary or early material replacement.

The digital evaluation is carried out via potential-free contacts that can be connected to the customer's plant control system. Our sensor system is therefore an extremely cost-efficient and reliable solution for monitoring wear on your systems.
Arrange a free sampling appointment immediately
smart plastics mini wear sensor (MWS)
smart plastics mini wear sensor (MWS)
Tech up

Tech up

  • Real-time status information for system parts subject to wear
  • Direct connection via potential-free contacts to plant control system (PLC)
  • Comprehensive connectivity for integration into predictive maintenance concept with i.Cee
Cost down

Cost down

  • Easy installation – equipment is glued to or screwed into the material to be monitored
  • Avoidance of unplanned downtime thanks to condition-based alarm messages


  • Ongoing test series in the industry's largest test laboratory for high-performance polymers


  • Minimal material requirements for the integrated sensor
  • Use-based product replacement reduces unnecessary material costs

IoT expert Richard Habering explains the use and benefits of the new low-cost sensors.

Intelligent condition monitoring implemented successfully

i.Sense from smart plastics in practice

Wastewater treatment plants and wastewater operations |
Port and container cranes
Conveyor and bulk handling


"Less effort, greater availability"

i.Sense EC.P in use "Less maintenance effort, greater availability, the capability of guiding all different cables and hoses in a single system, intelligent i.Sense condition monitoring … I would definitely choose the intelligent igus energy chains again!"

Dipl.-Ing. Fabian Wilhelm, Project Manager for AOS Stade GmbH

Customer applications worldwide

Overview of i.Sense examples Whether in international automotive production, the global crane industry or regional wastewater plants: i.Sense systems are successfully used and maintenance costs are saved and machine downtime prevented.

To the application overview

When do I need a smart condition sensor like the smart plastics MWS?

Condition monitoring instead of production downtime

When regular maintenance work requires complete production shutdown ...
Condition monitoring system for very small deviations

When motion anomalies cannot be detected by humans in time ... 
Condition monitoring for continuous monitoring

If plants or machines need to be monitored frequently or continuously ...
Condition monitoring for hard-to-reach areas

If energy supply system travels are difficult to access or view ... 
Condition monitoring for security areas

If maintenance work poses a health or safety risk ...
Condition monitoring for reducing costs

If maintenance costs are to be reduced and service life extended ...

Live condition monitoring in every bearing

i.Sense BRG for everyone

A defective bearing point can ruin the day, not only for farmers, but for any machine operator. Machine failures and downtimes are among the biggest cost drivers in industry. It is therefore important for maintenance personnel to act in good time to prevent unplanned stoppages.

igus smart bearing products are great for especially sensitive or hard-to-reach spots on a machine, since they allow the bearing's condition to be assessed at any time. The sensor can be used to monitor each machine wear part remotely – and this could benefit many other motion plastics applications in the future.
There are no limits to the application possibilities for the new mini-sensor.

Integration into your network environment

Since the new i.Sense BRG mini-sensor is part of the smart plastics i.Sense condition monitoring system, all of its data can also be evaluated in the i.Cee control cabinet module. These data can then be used to digitally control the system's alarm and escalation management. 

The i.Cee module can be integrated into predictive maintenance concepts in a number of ways, from preventive service management, which schedules regular maintenance depending on use, to location-independent fault management, which immediately reports any unforeseen change via various mobile channels. All information is collated in a modern dashboard, online or offline in the local network, depending on the customer's requirements.

General smart plastics overview

Insight into the entire igus Industry 4.0 product portfolio

Table of contents for this free brochure:
  • Condition monitoring (i.Sense)
  • Condition monitoring systems
  • Advantages of condition monitoring systems
  • Condition monitoring application examples
  • Predictive maintenance (i.Cee)
  • Systems for predictive maintenance
  • Advantages of predictive maintenance systems
  • Application examples for predictive maintenance
  • Data flow in modern smart factory concepts
Download the smart plastics brochure

Information ...

News catalogue: 2023 smart plastics news Read everything about 2023 smart plastics news again in a compact PDF format.
News catalogue PDF

... Try it ...

smart 3D data Free 3D data, operating instructions, and much more in our smart plastics service area
3D data

... Realise

Buy smart plastics news in the igus online shop Order ready-to-install smart plastics directly in the igus online shop
Online shop