Quiet, lightweight and maintenance-free sliding door with drylin telescopic rails and iglidur sliding element in the CAB from i:SY

What was needed: Quiet, maintenance-free sliding door guide with telescopic sliding function and sliding elements for the Cargo Box i:SY CAB

Requirements: Low-noise, low-maintenance and self-lubricating, insensitive to weather and dirt, lightweight

Sector: Bicycle industry

Success for the customer: Lubrication-free drylin telescopic rails in the sliding door and pressure sliding elements made of iglidur material ensure quiet, smooth-running and maintenance-free operation with a long service life; for prototype construction, i:SY uses iglidur filament in 3D printing to quickly test and optimise parts. The Cologne location and the associated proximity to igus ensure short transport routes and reduced emissions.

i:SY develops and designs in Cologne and manufactures in Germany - with the aim of designing bikes and accessories that are practical, modular and sustainable. For the CAB of the Cargo Maxi, a sliding door with remote lever was to be integrated, which makes everyday life with children, dogs or purchasing easier and is safe, comfortable and durable. The design requires moving components that work quietly, are easy to maintain and function reliably in changing weather conditions.

Build chamber and weight also played a role, so the add-on parts had to be as light as possible without compromising on service life. In addition to functionality and comfort, sustainability and assembly aspects had to be taken into account - materials with good recyclability and European production were the set goals.

The box itself is designed to be modular and internationally adaptable. The door can be hinged on the right or left depending on market requirements. This flexibility increases the complexity of moving parts - the slide and glide functions must perform reliably and quietly in different configurations. Lightweight, self-lubricating solutions were therefore required that could be quickly tested in prototype construction, iterated and then made available in batch production.

i:SY turned to igus at an early stage, as the product developer was familiar with their materials and expertise and was looking for a self-lubricating, quiet solution for the moving elements of the CAB. In the sliding door, drylin telescopic rails are used as well as pressure gliding elements made of iglidur material. This combination ensures low-friction, quiet and maintenance-free door operation - even under adverse weather conditions. The sliding components are corrosion-free, dirt-resistant and wear-resistant, ideal for long-term outdoor use on cargo bikes.

For the development, i:SY utilised in-house 3D printing and printed prototypes with iglidur filament sourced from igus, tested the components internally and then gave the tried and tested components to igus for series production using laser sintering printing. This shortened development cycles, reduced iteration costs and ensured the desired fit and smooth running of the sliding door at an early stage.

The solution supports the objectives of the i:SY CAB: the largest possible interior space with a compact design, lightweight, high recyclability and easy access to the cargo box. Overall, i:SY receives a robust, quiet and permanently lubrication-free door guide that fits seamlessly into the manufacturer's understanding of quality and sustainability. Another success factor is the local cooperation: i:SY and igus are both based in Cologne, which enables short delivery times and low transport costs - a synergy that significantly simplifies the development and assembly process.