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The design service

igus is renowned for supplying a large range of standard lubrication and maintenance free products. But did you know that our expertise spans far wider than just catalogue parts?

Every year, bespoke components are designed and manufactured at igus and the requirements for this is growing year on year. We offer advice, technical support and our expertise in the realms of "bespoke design" and have a dedicated team to support this.

Our Design Service supports customers requiring non-standard or technically complex solutions. Each individual enquiry is assessed, so we can identify the scope of the project, value, and complexity as these elements can vary significantly.

What we do

We provide advanced engineering design support for applications that extend beyond standard catalogue product ranges, including the design and development of customised or fully bespoke igus solutions. We also focus on the engineering modifications, validations, and optimisations of standard components in order to meet specific performance requirements. Our expertise supports technically demanding applications where standard products are either unsuitable due to load, speed, duty cycle or are restricted to space constraints, or environmental conditions.

Our engineering team consists of qualified, engineers with extensive industry experience. They ensure they deliver complex and technically challenging projects to a high quality and within the agreed lead time. The team use robust engineering methodologies, detailed analysis, and practical application knowledge, all while working closely with customers to develop reliable, application-specific solutions that meet performance, compliance, and lifecycle requirements.

How does the process work?

Two men discuss an IMPS face-to-face linear actuator at a trade fair stand.

Each project follows a structured design process:

  • Initial enquiry and review of the requirements
  • Technical assessment
  • Feasibility consultation with one of the engineering team (carry out design calculations using specialist tools)

Following on from the initial consultation, we may offer testing which can be conducted at our facilities in Germany or, where appropriate, at the customer’s own facility. Testing requirements and responsibilities are agreed as part of the project review.

Depending on the nature of the project, a nominal design fee may apply.

N.B at the initial consultation, we reserve the right to decline the project following on from the feasibility review

Examples of special customer bespoke design solutions

James Leckey mobility device

Child walking with an adult using a mobility walker in a corridor.

MyWay- the upright mobility device

An innovative design that supports children who cannot stand or walk. The wheeled frame allows children to propel themselves using their lower limbs, leaving their hands free to play.

MyWay was designed by Leckey and launched in Northern Ireland, after working with world leaders in design and paediatric postural support products.

Download the full power point

Challenge

The challenge was to make the adjustment of the MyWay as easy as possible, whist the child was in the support. The height adjustment was the biggest challenge. Requirement was for the slide to be adjusted across a range of 260mm in increments of 10mm and with a weight of up to 80KG being accounted for. As well as that, aesthetically it needed to work, preferably clean operations so no lubrication and as the force on the system was cantilevered, the sliding element was problematic.

Watch the video on how the adjustment works

Solution

The solution came in the form of a bespoke linear system based in a black anodised aluminium extrusion profile, drylin linear bearings in cast zinc housings. The extrusion aesthetically complemented the rest of the support, while the bearings offered a lubrication free, smooth movement and the housings could withstand the load.

Using 3D prototypes allowed flexibility in the design stage and being so impressed with the 3D print quality and functionality, the bearings were 3D printed for production.

See the profile and why igus was chosen

Calder Industrial Materials- radiation testing cell

Test rig with stacked components secured by orange straps in a laboratory.

Application

The application was a lead lined testing cell for safely testing radioactive materials for

The application called for a solution that could move the testing probe into position in two plains, both vertical and horizontal while radioactive material is housed in a lead safe.

Calder Industrial Materials.
igus gantry system with twin vertical columns, linear rails and actuator components.

Challenge

Challenge: The test cell is deployed 1km underground, so there is no access for maintenance. Therefore a maintenance free X&Y axis movement solution was needed and a requirement of a load: 3.5kN dynamic loading capacity and a speed 0.4m/min

Solution

A Bespoke linear system was designed and manufactured for the test cell. Horizontal: SHT-30 (with NEMA34 & 10:1 gear box), 2x AWMU-30 shafts, 4x OGA-30 bearings

Vertical: 2x SHTC-30 (drive unit with NEMA34 & 10:1 gear box), 2x heavy duty right angled gear boxes to link SHTC's, drive shaft & coupling's. Our energy chain was also designed in to protect the moving cables.

Special spherical and housing design

Square metal housing with a central tan bushing and four corner bolt holes.

Application

Application: Marine environment. Application was a hydrogen powered ship, the bearings were to support the hydrogen tanks. The requirements were a light weight, maintenance-free, durable bearing, that offered angular displacement of a shaft 20 degrees.

Two grey flange bearings with a spherical bearing insert aligned in between.

Challenge

Due to the requirements of the material, a standard option was not possible. The bearing material needed to have a ULV0 burn rated classification. Another requirement was a need for a 3kN static load.

Metal flange with a central bronze bushing and four mounting holes.

Solution

The solution was a complete bespoke housing and spherical ball. The housing material was machined in Aluminium 6082T6 and was coated in a Anodise; Class 25. The ball was manufactured in a ULVO rated material,

iglidiur RW370

Custom curved rail

Custom curved rail demo with a moving carriage on a circular track.

Application

A precision linear drive system with an integrated drive mechanism designed to transport and accurately position a spray head for the coating of luxury goods.

Curved rail assembly with standard rails and a central carriage on a test setup.

Requirements

Provide a closed-loop "racetrack" guide system to allow the spray head to transverse and be positioned at any point through 360° around the target object.

Curved igus rail segment with grey mounting bracket and toothed edge on a circular guide.

Challenge

Method for integrating a drive system within a rail profile configured in a closed-loop geometry, ensuring continuous smooth motion and minimal friction throughout the travel path

Solution

The solution involved integrating a machine rack directly into the base of an aluminium rail, resulting in a simplified assembly. The resulting "racetrack" configuration comprised of only two components, reducing part count and improving manufacturability.

Frequently asked questions

Depending on the nature of the project, the time and money investment for igus and the feasibility of the project, a nominal design fee may apply. All fees are subject to discussion and agreement prior to the commencement of a project.

All design enquiries should be submitted via our dedicated Design Services contact form to ensure efficient tracking and review by the appropriate technical team. The form allows you to upload files, photos and documents.

Normally we won't reverse engineer from existing parts however we are open to discussions regarding this issue so please do contact us.

The design rights are retained by igus, and manufacturing drawings are not released as part of the design service.

Yes we do, this can be discussed with the engineer

As with our standard range of products there is no minimum order quantity to our design service.

Meet the team

Our team of technical experts are here to support you. This dedicated team work with our customers to assist them with custom projects. For the initial enquiry please email Martin

Martin - Technical Sales Engineer for projects

Jon -Technical Project Engineer

Jonny - Lead Engineering Project Manager

Paul - Engineering Project Manager

Contact an expert