igus introduces 3D-printed wear-resistant turner to boost efficiency on high-speed packaging lines

SOUTH AFRICA – igus has developed a 3D-printed product turner designed to reorient cans and containers on high-speed packaging lines, offering manufacturers across Southern Africa a more durable and maintenance-efficient solution for downstream processing.

Engineered using the company’s proprietary iglidur i150 tribo-filament, the component is produced through additive manufacturing and is designed to withstand the continuous friction and load typical of automated packaging environments.

The polymer compound is tribologically optimised, meaning it is specifically developed to perform in high-wear applications where moving parts interact frequently.

According to Juan‑Eric Davidtz, the advanced material provides a significant improvement over conventional 3D-printing plastics used in industrial parts.

“The material used in the manufacture of the product is specially engineered for high abrasion resistance with excellent strength and mechanical properties,” Davidtz explained.

“Unlike standard polymers such as polylactic acid or acrylonitrile butadiene styrene, iglidur i150 contains solid lubricants that allow it to operate without external lubrication while delivering a longer service life in sliding and rotating applications.”

Traditional components used in conveyor systems often wear quickly due to constant mechanical stress, leading to production stoppages and higher maintenance costs.

The new polymer-based solution maintains dimensional stability for longer periods, reducing the frequency of part replacement and extending maintenance intervals.

The 3D-printed product turner has been designed primarily to reorient aluminium beverage cans and Polyethylene Terephthalate containers moving along high-speed conveyors in packaging facilities.

However, igus says the design can also be adapted to suit other packaging and product handling requirements depending on customer specifications.

A key advantage of the technology is the speed and flexibility offered by additive manufacturing.

By using 3D printing, igus can rapidly prototype and test custom designs before scaling up to production-grade components, allowing manufacturers to respond quickly to changing production demands.

For food and beverage applications, the iglidur i150 material is compliant with EU Regulation 10/2011 when properly specified, making it suitable for use in packaging environments where hygiene and regulatory compliance are critical.

The solution is supported by igus’ in-house 3D printing service, which produces a range of motion and wear components including plain bearings, gears, and custom rollers using the company’s proprietary polymer materials.

These parts are designed to operate without lubrication and require minimal maintenance, helping packaging manufacturers improve operational reliability.

As packaging lines become increasingly automated and high-speed, manufacturers across the food and beverage sector are exploring advanced materials and additive manufacturing technologies to reduce downtime, improve equipment lifespan, and optimise production efficiency.

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