igus develops flexible and strong energy supply systems for individual cables – designers wanted for pilot projects

Whether in food-vending machines, laboratory equipment or electric doors: whenever space is at a premium, designers often dispense with guides for individual moving cables – and thus risk cable damage and unnecessary maintenance costs. A new, one-piece, injection-moulded and particularly compact energy chain made of high-performance plastic from igus is designed to put things right. As this product is currently still a design study, the Cologne-based motion plastics specialist is now looking for interested companies that would like to use the energy supply systems in pilot projects and develop them further to series production.

In simple applications, designers have often dispensed with guides for individual cables altogether, be it for reasons of space, due to costs or because the movements appear to be too small. “The cables then often move freely or are held roughly in position by cable tiewraps,” explains Kira Weller, Product Manager e-chains at igus. However, designers accept certain risks. Without defined guides, the cables move uncontrollably and can chafe, kink or, in the worst case, break. This leads to malfunctions, increased wear and unnecessary maintenance costs.” To close this gap, igus is developing a new one-piece energy chain in the E1 series. It was first unveiled as a design study at the Hannover Messe in 2025. “We received positive feedback from designers around the world who have been searching in vain for a cost-effective cable guide solution for compact installation spaces. This motivated us to press ahead with development,” says Weller.

Cost-effective and compact energy chain from one piece

The special feature of the energy supply is its one-piece design, produced in a single injection-moulding process. This makes the product more cost-effective than energy chains consisting of several assembled chain links. It gives the cable stability in very small installation spaces and thus provides a longer service life for the system. In addition, the easy-chain principle makes assembly easier. Users can push the cable through the flexible teeth without tools, which secure it firmly on both sides and protect it from external influences. The guide can then be attached with integrated mounting brackets, which ensures movement with a controlled bend radius.

igus seeks cooperation with interested engineers

To accelerate the transition to high-volume production, igus is currently looking for design engineers who are interested in pilot projects. The company wants to adapt the e-chain to various applications. This is not just a question of length. Even extremely short movements of only 40mm are possible, for example when moving electrical objects. Several materials are also available for injection moulding, including the high-performance plastic igumid NB, which is characterised by wear resistance, resilience and chemical resistance. “We want to work with users to take the final steps towards series production,” says Weller. “We welcome everyone who wants to bring their ideas to life with us.”

Product testers can register via this link:
https://www.igus.eu/service/contact/e1-request