For the first time, the sensor technology is printed into the additively manufactured tribo-component using multi-material printing. "We have now achieved a real breakthrough with the smart 3D-printed bearing," says Tom Krause, Head of Additive Manufacturing at Igus. "This makes predictive maintenance possible in a cost-saving way, even for special parts." The component signals that a replacement is imminent long before it fails. It can also detect overload in order to stop the application immediately and thus prevent further damage to the bearing point and the entire system.

Wear or load is monitored

Igus has been producing intelligent wear parts in energy chains, plain bearings and linear guides since 2016. Initially, plain bearings were produced from Iglidur I3 using laser sintering and the intelligence was subsequently introduced in a second processing step. However, the production of intelligent special parts in small quantities is complex and expensive in this case, as the downstream work steps are very specifically designed for the respective component.

Thanks to a new process, the developers are now able to produce such intelligent wear parts in just one work step. No further processing steps are necessary and intelligent special wear parts can be produced cost-effectively from 5 working days. The sensor layer is applied to the areas of the component that are subject to stress. Wear-resistant components with integrated sensors are created using multi-material printing. The components are made from Iglidur I150 or Iglidur I180 filaments and a specially developed electrically conductive 3D printing material that bonds well with the tribofilament.

Two areas of application are currently possible: if the electrically conductive material is located between the layers subject to wear, it can warn of overloading. This is because if the load changes, the electrical resistance also changes. The machine can be stopped and further damage can be prevented. To determine the load limits, the bearing must be calibrated accordingly.

If, on the other hand, the conductor track is inserted into the sliding surface, the wear can be measured via the change in resistance. Predictive maintenance is possible with the 3D printed component. The lubrication- and maintenance-free Tribo component indicates when it needs to be replaced, preventing system downtimes in advance and allowing maintenance to be planned. If the 3D-printed components are also used in the pre-series stage, the wear or load data collected provides additional information in advance about the service life of the individual component or the planned application in series production. This makes it easier to make adjustments and optimizations during the development process.