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e-chains®, chainflex®, cables, harnessed systems readychain®

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dry-tech® bearing technology

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Smart solutions for condition monitoring and predictive maintenance

Extend product service life and reduce maintenance costs with igus smart plastics

There is no automation without digitalization: The direct route is condition monitoring with i.Sense, which offers rapid integration with maximum reliability. If, on the other hand, you want to completely network your manufacturing plants with the Internet of Things (IoT)predictive maintenance with i.Cee is exactly the right choice.

With smart plastics – energy chain systems, chainflex cables, and plain bearings equipped with smart sensors – igus is pursuing the goal of making complex automation solutions Industry-4.0-compatible as easily as possible.
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Want to avoid plant downtimes and make maintenance plannable? How this works with igus can be seen in this video ...


smart news 2022

smart plastics news 2023 ...

... experience now all smart plastics 2023 new products like the breakage monitoring for robot chains i.Sense TR.B or for the first time the new smart all-round service superwise right here:
Industry 4.0: 2023 smart plastics News - overview

Condition monitoring (i.Sense)

Condition monitoring is the fastest, simplest way to combine many igus® products to form a self-monitoring smart plastics product. Sensors are mounted to measure values (such as temperature, forces and sound waves/vibrations) within pre-defined limits. Values outside the limits result in an alert or at least a notification. This information provides the basis for taking subsequent steps, such as maintenance or shutting down the system. As desired, values outside defined limits can directly trigger a system shut-down in order to prevent damage that is expensive to repair.
At igus®, we use the term "i.Sense" to refer to condition monitoring.
Go to condition monitoring

Predictive maintenance (i.Cee)

Predictive maintenance uses sensors, software, and the elements of condition monitoring to create a system that allows dynamic service life calculation and determines the best times for the maintenance of igus® products. This makes predictive maintenance the next step in achieving a comprehensive concept for smart energy supply and bearing technology. This predictive maintenance system is called "i.Cee" and is available in a wide variety of designs, offering a high degree of individuality. The goal is always to maximise system and user safety and product service life.  
We call our predictive maintenance system "i.Cee".
Go to predictive maintenance
smart plastics infographic

These products can be equipped with smart plastics technology

General smart plastics overview

The brochure provides a quick overview

Topic overview:
  • Condition monitoring (i.Sense)
  • Condition monitoring products
  • Condition monitoring application examples
  • Predictive maintenance (i.Cee)
  • Application examples for predictive maintenance
  • Predictive maintenance data flows
Download brochure

What would you like?

Predictive maintenance smart plastics Are you looking for a shut-down function for your energy supply system in order to avoidcrash?
Predictive maintenance smart plastics Are you trying to avoid software for monitoring your energy supply?
Predictive maintenance smart plastics Do you want status reports to be displayed with LEDs?

Predictive maintenance smart plastics Do you want the current service life of your igus® products displayed at all times?

Predictive maintenance smart plastics Do you want to know when one of your igus® products should be maintained?

Predictive maintenance smart plastics Do you want to avoid unscheduled machine downtime?

Predictive maintenance smart plastics Do you want to make your energy supply and plain bearing technology Industry 4.0-capable?

Predictive maintenance dashboard Would you like to see right now what will happen in the future?

Predictive maintenance news You can find more predictive maintenance area capabilities in the Smart Factory in our news overview.

Industry 4.0: successfully implemented in practice

Cranes Machine tools Woodworking industry Material handling Robotics Bulk handling Offshore Explore all applications

Automotive production

Predictive maintenance in automotive production In automotive production, the assembly lines never stand still. Smart production concepts in the style of predictive maintenance have long been established in these production lines.
Find out more

Crane industry

Condition monitoring of cranes Heavy loads, long periods of use, and a wide variety of weather conditions – cranes must present a fantastic performance. To ensure this at all times, reliable condition monitoring concepts are needed.
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Wastewater and sewage treatment plants

Smart condition monitoring of wastewater treatment plants Wastewater treatment plants demand a lot from the components used: continuous operation, weather and dirt. Our intelligent energy chain systems are designed for fail-safe operation at all times under all conceivable conditions.
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Bread wrapping machine

Bread wrapping machine "igus® CF.Q condition monitoring can prevent failure of machines with high output", says Dipl.-Ing. Oliver Tausch, Head of Electrical Engineering, of GHD's required specifications.

Austrian automotive supplier

Austrian automotive supplier An Austrian automotive parts supplier uses smart plastics from igus for its indoor gantry cranes, which automatically handle engine blocks.

Aluminium oxide production

EC.P at AOS "If movement of the chain is excessively hindered by dust or dirt, the push/pull monitoring shuts down the system before any damage can occur"

Train washing station

smart plastics train washing station Always clean trains and safe energy supply thanks to predictive maintenance with igus i.Cee.

Linear robots

smart plastics Güdel Due to the integration of smart plastics sensors into the energy supply, the customer's condition monitoring system is supplied with data.  

Sewage treatment plant

smart plastics in sewage treatment plants No nasty surprises thanks to conditioning monitoring in especially slow applications, where damage is difficult to see and usually only become visible when it is too late.

smart plastics FAQs

FAQ & integration

What are igus smart plastics? What is Industry 4.0? In our blog, you will find answers to the most frequent questions on this topic:

3D CAD portal for smart plastics

Design smart energy chains in the 3D CAD portal

Design intelligent energy chain systems faster. CAD models for all smart components.

Our intelligent e-chain systems are already reliably in use in hundreds of thousands of applications worldwide - from beverage machines and CNC machines to steel mills. Unsupported lengths can be bridged without problems and long travels are conceivable for the most varied of industries. 
To the 3D CAD portal for smart components

Further information material:

smart plastics catalogue

Stay up to date with our latest product catalogue including all facts and figures for smart plastics: 
► Browse interactive catalogue


Every year, more than 3,000 tests are carried out to collect sufficient data for the service life algorithm. 

Recycling programme

Ask igus to recycle your energy chains, irrespective of the manufacturer. How does it work?

Online seminar

Benefit from the experience of our speakers:
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The terms "igus", "Apiro", "chainflex", "CFRIP", "conprotect", "CTD", "drylin", "dry-tech", "dryspin", "easy chain", "e-chain", "e-chain systems", "e-ketten", "e-kettensysteme", "e-skin", "e-spool", "flizz", "ibow", "igear", "iglidur", "igubal", "igutex", "kineKIT", "manus", "motion plastics", "pikchain", "readychain", "readycable", "ReBeL", "speedigus", "triflex", "robolink", "xirodur", and "xiros" are legally protected trademarks of the igus® GmbH/ Cologne in the Federal Republic of Germany and where applicable in some foreign countries.

igus® GmbH points out that it does not sell any products of the companies Allen Bradley, B&R, Baumüller, Beckhoff, Lahr, Control Techniques, Danaher Motion, ELAU, FAGOR, FANUC, Festo, Heidenhain, Jetter, Lenze, LinMot, LTi DRiVES, Mitsubishi, NUM,Parker, Bosch Rexroth, SEW, Siemens, Stöber and all other drive manufacturers mention on this website. The products offered by igus® are those of igus® GmbH