The Lightweight Advantage of igus Motion Plastics
By Shizu Yamaguchi, written with the use of Copilot GenAI
Excess mass slows everything down. It increases energy consumption, adds load to actuators, and often complicates both installation and long‑term maintenance. That is why the lightweight characteristics of igus motion plastics deserve attention from any engineer engaged in designing a robot or machine with moving parts.
Cut the weight. Improve performance.
igus high‑performance polymers offer weight reductions of up to 70 percent when compared with metal parts. A lighter assembly responds faster, accelerates more efficiently, and places far less strain on motors and drive systems. These advantages matter to machine builders who are pushing for higher throughput and more responsive motion profiles. They also matter to engineers working in space constrained environments, where even a gram can influence system performance. [igus.eu]
Built tough. No compromises.
In industries like aerospace, automotive, and medical, lightweight design is often treated as a requirement rather than a preference. igus engineered polymers have established a strong presence in these categories because they support meaningful reductions in payload while still offering the durability needed for harsh environments. Their ability to withstand vibration, temperature swings, and chemical exposure makes them practical for applications where reliability is non-negotiable. Engineers prefer solutions that do not force tradeoffs between durability and mass, and igus materials demonstrate that this balance is achievable. [milaerosolutions.com]
Cut costs.
Reducing component weight has a clear connection to lower operating costs. When a system uses lighter bearings, guides, or energy chains, the mechanical load on actuators decreases. This leads to longer component life and reduced energy consumption, two benefits that are increasingly important as manufacturers focus on efficiency and sustainability. Many companies that transition from metal to motion plastics report not only improved performance but also reductions in long term maintenance requirements. These trends show why lightweight design should be considered early in the engineering process rather than as an afterthought. [igus.eu]
Greener machines.
The shift toward lighter materials plays an important role in achieving sustainability objectives. Reduced mass lowers emissions associated with shipping and improves energy efficiency during operation. igus strengthens this advantage through new sustainable product lines. These include recycled energy chains and the glide chain G4.42 series, a design that represents a 12 to 25 percent mass reduction over conventional models. This type of innovation is increasingly important as manufacturers seek solutions that improve performance while supporting responsible material use. [ourmechani…center.com]
Bonus: Solid lubricants – WIIFY.
Engineers appreciate that igus components contain built in solid lubricants. This eliminates the need for external lubrication systems, which typically add mass, create contamination risks, and require regular servicing. A lubrication free solution remains clean, reduces downtime, and avoids the complexity of managing grease or oil in sensitive applications. When weight reduction is paired with maintenance free operation, the result is a system that is both lighter and more dependable. [igus.com]
Final thoughts.
Lightweight engineering is not simply a trend. It is a defining factor in the performance, reliability, and energy efficiency of modern machinery. igus motion plastics demonstrate how substantial reductions in mass can be achieved without sacrificing structural integrity or environmental resistance. For design engineers and mechanical engineers, the implications are clear. A system built with lighter components performs better, costs less to operate, and delivers greater long term value.
Have a project in mind you’d like to discuss? Reach out to us for in-person assistance from one of our technical experts. We can be reached by phone at 1-800-965-2496, via live chat at igus.ca, email at CAOrdersNA@igus.net or by contact form.
