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smart plastics new products
The growing importance of smart condition monitoring and predictive maintenance
The integration of IIoT into industrial processes simplifies condition monitoring and predictive maintenance. With our new products, we are moving further in the direction of Industry 4.0. Sensor-based information enables us to make an exact statement about the expected service life of the products. Downtimes can be reduced and production efficiency increased. We are constantly developing our products to enable precise maintenance planning and to provide accurate information on the condition of the system at all times.
News 2026
PLACEHOLDER for visual - currently being created
The new DMS force sensors.
Proven protection, now with cable diagnostics.
Every minute counts when it comes to service - and with sensor systems, it is not always immediately clear whether an actual force limit has been exceeded or whether a cable fault is triggering the alert. The new generation of the proven strain-gauge force sensor adds an additional level of diagnostics to force monitoring: The sensor can now detect cable breaks and contact faults in the cable connected to it, making troubleshooting considerably easier. This reduces time and effort in diagnostics, shortens downtimes, and increases system availability.
The new generation of sensors remains practical: It is compatible with existing i.Sense systems and can be integrated into existing installations via a firmware update. In addition, igus supplies the sensor as an installation set including cable, dummy, and mounting material, so that assembly is completed quickly.
A comprehensive overview of the suitable sensor technology - the EC.P push/pull force monitoring can be found here.
i.Cee² measurement case.
Mobile measurement campaigns directly on site.
In everyday life, many measurement tasks fail not because of the sensor technology, but because of the effort: assembling, cabling, supplying and connecting devices - and in the end something is still missing.
The i.Cee² measurement case (design study) therefore pursues a simple approach: an integrated measurement platform in a portable industrial case. Open the case, connect the sensor, start the measurement.
This allows measurement data to be recorded directly on machines, systems or test rigs and evaluated on site - without fixed installation and without long preparation. If you would like to set up measurement campaigns faster and obtain results where the data is generated, you will find all the information and the option to register as a beta tester on the detail page.
TR.P measurement case.
Making tensile forces in the robot dress pack visible.
Robot programs can run perfectly - and yet the dress pack suffers: jerky movements, unfavourable accelerations or overextensions often go unnoticed during operation until wear or downtime occurs.
The TR.P measurement case (design study) makes these loads measurable. As a mobile solution, it records, visualises and analyses the actual tensile forces in the triflex® system during actual robot movements.
This helps programmers identify critical movements during commissioning and enables service and operations teams to assess recurring problems more quickly. You can find out how the measurement case is used - and how you can register as a beta tester - on the detail page.
From concept to product.
TR.P makes robotics smarter and safer.
The TR.P tensile force sensor system brings a new level of intelligence to industrial robotics.
It recognises critical movements before they cause trouble. Tensile forces are measured directly at the head of the triflex R system. A reaction to predefined force limits being exceeded is immediate - either with a clear message or an automatic stop.
This enables risks to be eliminated at an early stage and consequential damage to be drastically reduced during operation.
For elegant technology. For robust processes.
Robotics that think ahead.
Real time. Simple. Everywhere.
The i.Sense display brings condition monitoring to the outside world.
The new i.Sense display brings all relevant data from the control cabinet directly to the control cabinet door and takes your maintenance processes to a new level.
Developed for modern industrial environments, it combines robust hardware with intuitive operation and ensures that your team has a complete overview at all times.
Be it a live display of critical sensor data, system resets or parameterisation - all this can now be done without opening the control cabinet.
As an official accessory for smart plastics solutions, the display fits seamlessly into your condition monitoring setup.
Make your floating moving end smart – just like that
The Kombi FTA turns a tried-and-tested floating moving end into an intelligent sensor carrier.
The extension kit adds real-time perception along the entire guide trough to the existing mechanics – without adapting the build chamber, without design changes, without compromises.
superwise & ServiceCare.
Maintenance taken further.
The superwise service packages transform maintenance into clarity: A scalable, data-based after-sales system that identifies risks, simplifies decisions and keeps systems running reliably – before a problem arises.
superwise is based on test and field data from real smart plastics applications. Portal, dashboard and event histories provide the basis for comprehensible, data-based decisions instead of gut feeling.
Precise, usage-based recommendations lead to the avoidance of unnecessary material changes and noticeably extend the system service life.
i.Cee² - Two worlds. One device.
The new simplicity of industrial intelligence.
i.Cee² is the further development of the tried and tested i.Cee module.
In addition to the core functions of the superwise system for e-chain systems, the new module goes far beyond condition monitoring: As a fully-fledged Industrial Edge computer,
it can be integrated into completely new applications such as data logging or edge analytics.
i.Cee². Open. Modular. Limitless.
News 2025
i.Sense condition monitoring
for vertical e-chain systems
The familiar push/pull force and breakage monitoring is now also available for vertical e-chain® applications with guidelok slimline (GLSL.P).
The integration of i.Sense increases the service life of the application and avoids failures and unplanned downtimes. This enables safe operation beyond the product life cycle.
The application can be integrated into the superwise environment with all the associated benefits.
EC.WLC - the mechanical status indicator now also for the E4.Q system!
Red, yellow, green – like a traffic light, the mechanical status indicator shows the wear status of the gliding e-chain®. Without any electronics. Now also for the E4.Q system.
BLE data concentrator -
Planning reliability via IoT
The data concentrator receives wear or consumption information from all igus® sensors and transmits it to the superwise portal via IoT.
This digital interface enables automated data management, for example for smart drytech bearings or the intelligent chainflex CASE, which saves resources by reducing the amount of ordering and monitoring required.
In addition, the efficiency of the customer's purchasing department can be increased through automated ordering concepts or active contact on the part of igus®.
A (genuinely) smart sensor -
the BLE drylin® W condition monitoring system
The two-stage sensor element with microcontroller for data analysis offers real-time monitoring and predictive maintenance of drylin® W linear guides.
Integration into the superwise infrastructure enables automated reminders for replacement measures and ordering of retrofit parts. Unnecessary repairs and replacements are a thing of the past.
Smart monitoring of stocks -
Intelligent residual length measurement
for chainflex CASES
Intelligent residual length measurement for monitoring cable stocks and as a basis for automated reordering.
This improves the efficiency and reliability of cable management systems and helps to avoid wasted time due to missing cables.
Reorders can only be placed when required, as stocks are available by type.
Planning for tomorrow with igus® and superwise
superwise offers customers the opportunity to request services online, communicate directly and keep an eye on all connected igus® components on a dashboard.
Direct communication with the service team and one-click orders for spare parts, maintenance work or monitoring devices ensure overall system effectiveness at all times.
Currently, more than 1000 customer applications connected to the system are continuously monitored, thus reducing unplanned downtimes.
Extended possibilities -
Firmware release for
i.Sense condition monitoring
Maximum efficiency in condition monitoring: The new firmware of the proven i.Sense condition monitoring module offers motion profile measurement for the use of e-chains® on long travels as well as freely programmable alarm contacts.
The motion profile measurement of the e-chain® via the breakage detection sensor provides information about the condition of the e-chain®. Integration into the superwise environment is possible.
The additional alarm via the NC contacts simplifies software integration and saves programming time.
