Your complete igus campus in Cologne, the place it researches, produces, and checks, now covers round 218,000 sq. m (2.3 million sq. ft.). Supply: igus GmbH

From movement plastics to humanoid robots, igus GmbH has continued to innovate. Regardless of financial constraints and geopolitical tensions, the Cologne, Germany-based firm yesterday introduced that it made €1.105 billion ($1.19 billion U.S.) in gross sales final yr. It’s providing a document variety of 277 new lubrication-free movement plastics merchandise for 2025.

“The altering political and financial situations didn’t depart us fully unaffected,” acknowledged Tobias Vogel, CEO for plain bearings and linear know-how at igus. “Like lots of our clients, we’re additionally specializing in financial savings and elevated effectivity, e.g. via elevated automation in our manufacturing unit.”

“Nevertheless, our focus is at all times on the query: What’s in it for the client?” he added. “These challenges are a fair better incentive for us to interrupt new floor and show our progressive power ‘made in Germany’ to strengthen each our competitiveness and that of our clients.”

Whereas the VDMA Robotics + Automation Affiliation has expressed concern that the German robotics trade has misplaced competitiveness, igus has elevated the variety of energetic clients by 5%. The corporate reported a comparatively reasonable decline in turnover of two.5%.

Based in 1964, igus develops and produces movement plastics, that are lubrication-free, high-performance polymers. The family-run firm mentioned it’s the international market chief in vitality provides, versatile cables, and plain and linear bearings, in addition to lead screw know-how fabricated from tribo-polymers. It employs 5,200 folks worldwide and has U.S. amenities in Rumford, R.I.

Low Price Automation addresses extra functions

“There may be nonetheless loads of potential for innovation in German trade,” mentioned igus, which cited its Low-Price Automation growth work for example. Its RBTX on-line market consists of configuration instruments, free consulting and software testing, and quite a few merchandise for lean robotics functions.

“We provide over 200,000 components for automation,” famous Alexander Mühlens, vice chairman and head of the Low-Price Automation enterprise unit at igus. “There are too many boring jobs, even inside igus.”

Purposes appropriate for automation, even at igus, embody palletizing and bringing components to molding and drilling machines, he instructed The Robotic Report in the course of the firm’s spring media name.

“We’re beginning with AMRs for inside and out of doors functions,” mentioned Mühlens.

As well as, igus presents assist with integrating all of the applied sciences it presents. “Robotics customers must combine cameras with robots,” he mentioned. “Our reply is the Robotic Management software program, which makes it simple to combine cameras with our SCARA robotic and ReBeL cobots.”

Whereas about 30% of igus’ collaborative robotic arms are utilized in training, 70% are in industrial functions corresponding to high quality management, pick-and-place operations, drilling, CNC machine tending, gluing, and printing, Mühlens mentioned.

On the 2025 Robotics Summit & Expo, which will likely be on April 30 and Might 1 in Boston, igus will exhibit the next applied sciences at Sales space 221 on the present flooring:

• The “axis” on-line neighborhood for the trade
• The ReBeL EduMove cellular manipulator utilizing open-source software program for training and analysis
• The igus Robotic Management software program

Jan Hennecke, Low-Price Automation product supervisor at igus, will current a session on “Learn how to Get Your First Robotic Into the Manufacturing unit” on Wednesday, April 30.

Register now so you do not miss out!

igus is constructing its first humanoid

The corporate is growing its first humanoid robotic fabricated from high-performance plastic, notably for its transferring components. The system is predicated on igus’ ReBeL Transfer wheeled cellular robotic, and ReBeL light-weight cobot arms.

“It may be used flexibly and from any location at completely different workstations — with a return on funding [ROI] of lower than one yr,” the corporate asserted.

As for goal markets for its humanoid, igus is open to buyer suggestions, Mühlens mentioned. Instance functions embody greeting clients and a few insertion and meeting duties in factories.

“When it comes to threat analyses, humanoids are simpler to begin with in manufacturing vegetation than in eating places,” mentioned Mühlens, who added that the robotic will likely be designed for protected human-machine interplay.

“Humanoids are the longer term in a world designed for people,” he mentioned. “We’ll be presenting at Hannover Messe 2025.”

According to its motto, ‘Go Zero Lubrication,’ igus is presenting 277 plastic improvements this yr, from PTFE-free supplies and a whole vitality chain collection made out of recycled supplies to a humanoid robotic. Supply: igus GmbH

Movement plastics chief appears to spice up sustainability

Along with presenting 277 new movement plastics merchandise, igus is constant to spend money on the analysis, growth, and manufacturing of progressive applied sciences. The corporate mentioned it’s producing a model of its igludur plain bearings freed from polytetrafluoroethylene (PTFE or Teflon) at related value factors and efficiency to straightforward bearings.

igus is changing its whole E2.1 collection of vitality chains to recycled materials from previous fishing nets and vitality chains that it recycles as a part of its Chainge program. It claimed that it will scale back the CO₂ footprint by 80%.

The corporate mentioned it has reached 92% towards its goal of being CO₂-neutral with its buildings and manufacturing by the top of 2025, measured in opposition to Scopes 1 and a couple of.

“We have to develop into even higher on this space and are engaged on quite a few sustainability measures, from the brand new multi-story automobile park with full façade greening to the modernization of our current buildings … with photovoltaic techniques to the growth of our MHRS system for heating with waste warmth from machines,” defined Michael Blass, CEO of e-chain techniques at igus.

The corporate additionally introduced the igus Cell Shore Energy Outlet (iMSPO) for the shore energy provide of container and cruise ships. The system is already in use in ports corresponding to Hamburg, Rotterdam, and Singapore.

With Fraunhofer IPA, igus has developed a brand new certificates that confirms the cleanroom suitability of its e-chains in long-term checks. They’ll stand up to over 15 million double strokes with minimal and constant particle emissions, which is necessary in battery manufacturing.

With its emphasis on controlling prices for purchasers, igus is providing the brand new G4.42 vitality chain for easy gliding functions corresponding to on indoor cranes with journey distances of as much as 30 m (98.4 ft.). Because of the G4.42’s optimized design, it isn’t solely 12 to 25% lighter, but additionally 30% to 40% more cost effective than normal chains of the identical dimensions from the E2 and E4 product vary, mentioned igus.

The corporate famous that it has expanded by creating inside startups for techniques corresponding to ball bearings, robotic drives, 3D printing, and clever “sensible plastics” for Business 4.0. It additionally confirmed off the largely plastic RCYL bike, which is at the moment on a world tour to point out the probabilities of recycled supplies with igus engineering.

The igus low-maintenance bicycle made out of recycled plastic is now on a world tour. Supply: igus GmbH

igus invests in German, international presence

“Within the final 5 years, we’ve got invested over €350 million [$377.2 million] in Cologne alone — in land, buildings, state-of-the-art machines, software program, new merchandise, folks and advertising,” mentioned Vogel.

With final month’s acquisition of elko Verbindungstechnik, which produces cables and plug-in connectors utilized in machine instruments and the automotive trade, igus is increase its meeting capability in southern Germany. At its Cologne headquarters, igus is investing in automation corresponding to specifically developed and patented crimp towers and automatic guided automobiles (AGVs) in its manufacturing unit buildings.

The corporate has additionally expanded its manufacturing corridor and check laboratory in Germany, in addition to in its branches in Shanghai, China, and Bangalore, India.

“The shopper is on the middle of all our actions,” mentioned Blass. “After introducing injection molding within the U.S., we’re now additionally organising on-site lead screw manufacturing and have opened our personal RBTX buyer testing space for low-cost robotics.”

“Which means 10 international locations now have their very own buyer check areas in order that customers can shortly and simply discover their particular person Low-Price Automation answer on website,” he mentioned. “Three of those areas — USA, China, Brazil — will likely be expanded into regional hubs, in order that manufacturing and growth will even be more and more localized. We’re additionally investing within the growth of branches in different international locations corresponding to Japan, Spain, Taiwan and Poland.”

Dave Williams, is the Senior Principal at PAE Engineers, he has 20 years of expertise in mechanical engineering. By means of his in depth work with knowledge facilities, laboratories, and healthcare amenities, he has turn out to be exceptionally expert at offering designs for managed environments. Dave focuses on decreasing working and upkeep prices, and rising vitality effectivity. He counts Kaiser Permanente, Legacy, Tuality, and PeaceHealth amongst his long-term purchasers. A LEED Accredited Skilled, Dave has labored on many sustainable tasks, together with a number of LEED and Internet-Zero Vitality licensed buildings.

PAE Engineers makes a speciality of designing energy-efficient, high-performance knowledge facilities that prioritize sustainability and operational effectivity. Their work integrates modern cooling options and superior engineering to optimize efficiency whereas decreasing environmental impression.

Can you’re taking us again to your first expertise designing an information middle? What was the undertaking, and what had been a few of the largest challenges or studying moments you encountered?

The primary main was memorable and, actually, certainly one of my favorites.  It was a conversion of an previous semiconductor facility into an information middle.  That conversion, as you possibly can think about, had a number of challenges, from repurposing the gear to totally different working situations, including resiliency, and making certain correct operation with the reuse of apparatus was difficult.  Commissioning was fairly difficult as effectively, and making certain all parts, particularly the cooling gear and controllers, might ramp up shortly on an influence failure created some fascinating and enjoyable challenges to resolve.  Ultimately, all of it labored nice, and the staff actually bonded within the collaboration of many gamers to execute and switch over an excellent work knowledge middle facility.

How have knowledge middle design priorities shifted within the final 20 years? What are the largest modifications you have seen in cooling, energy distribution, and redundancy?

Priorities have shifted fairly a bit.  Information facilities exist to supply a resilient, high-uptime atmosphere for servers.  As servers have turn out to be considerably extra highly effective and adaptable to environments, the amenities have modified.  They’ve turn out to be very environment friendly, pushing the envelope of vitality effectivity from the transformation and transportation of energy to the racks, and the HVAC techniques that present a steady atmosphere for the amenities to function in have modified from massive power-consuming gear to modern high-efficiency techniques that enable for a lot decrease PUE’s than ever earlier than.

What are the largest challenges in designing knowledge facilities proper now? How do components like energy availability, cooling capability, and stricter laws impression design choices?

The provision of dependable energy is usually the most important think about finding an information middle. Land availability, proximity to fiber, safety, and local weather issues all think about, however discovering energy appears to be a giant driver.

How does PAE Engineers combine sustainability into knowledge middle tasks from the preliminary planning phases?

Beginning with the tip in thoughts is at all times an excellent reminder.  Sustainability is a broad time period that’s extra than simply vitality, however with the quantity of vitality wanted, that usually will get probably the most consideration.  Setting targets for low PUE and sticking to that by the course of design is a guiding gentle and helps form choices.  As famous earlier than the purpose of an information middle is to energy the servers.  Some other vitality used on the facility helps that and is the place we need to focus our efforts on decreasing it.  Cooling techniques are the primary offenders on this, and beginning there may be actually the place we like to begin.  Contemplating the local weather the ability shall be positioned in and optimizing the system to maximise free cooling and contemplating methods to keep away from refrigeration techniques with massive compressor motors actually helps the effectivity.  Subsequent assessment of warmth restoration with assist areas from the info halls, water discount measures, controls optimization, and even issues like renewables and rainwater seize are extra objects thought-about when designing for a excessive stage of sustainability within the facility.

What are probably the most promising improvements driving vitality and water effectivity in knowledge facilities as we speak? 

As servers turn out to be extra resilient and in a position to deal with hotter temperatures, the flexibility to extend the hours within the yr without cost cooling has actually had an impression. Due to this, most of the knowledge facilities deployed now have a few of the most modern and energy-efficient techniques put in. Liquid cooling with extra dense capability servers brings new challenges and alternatives, as water has far more potential for large-scale warmth switch than air.

How do you steadiness high-performance computing calls for with sustainability targets? Are there trade-offs when decreasing PUE (Energy Utilization Effectiveness) or water utilization whereas sustaining reliability?

Not if finished accurately. The infrastructure should assist the wants of the server racks with a resilient deployment, but when finished thoughtfully, it may be optimized to operate very effectively, decreasing the PUE and water consumption with out compromising the compute’s efficiency calls for.

What challenges do you face when implementing renewable vitality, superior cooling, or different sustainability measures in high-density knowledge facilities?

The challenges differ from undertaking to undertaking. Typically, there could also be native code or jurisdictional hurdles to beat, land is probably not accessible to deploy a sure kind of system, or actually, based mostly on the fee to implement an modern design, the profit would not justify implementing it. What works effectively for one local weather or website is probably not the perfect for one more, so every undertaking ought to take into account this.

How are AI workloads altering knowledge middle design? What changes are wanted for energy and cooling to assist high-density AI racks?

Densification can have an effect on each the facility and cooling techniques fairly a bit. Bigger feeds, breakers, piping, and so on., all supporting a way more localized energy load create challenges, but in addition alternatives to rethink how the infrastructure needs to be laid out, positioned, and deployed in a approach that’s secure, resilient and useful.

What function do you see AI enjoying in optimizing vitality effectivity and real-time operations in knowledge facilities?

It’s large.  The power to create a machine studying facility that deploys large computing energy in the direction of the optimization of energy-consuming techniques that serve not all knowledge facilities however the constructed atmosphere in totality is big.  Peak shaving, understanding how every facility varies in its operation, and optimization on a selected case-by-case foundation is a big alternative.  Rolling compute throughout a number of amenities in real-time with adjustment to various local weather zones.  I can solely think about how a lot AI learns in regards to the operation. The options and optimization it might deploy would have an enormous impact on how the techniques that serve these amenities will be adjusted and tuned.

What may the following technology of AI-driven knowledge facilities seem like? Do you anticipate widespread adoption of immersion cooling, onsite renewable energy, or absolutely automated amenities?

Frequently higher-density racks are the development and can seemingly proceed for a couple of years.  That densification creates fascinating alternatives for the bodily measurement of information facilities with doubtlessly smaller footprints, but in addition new issues to think about relating to infrastructure like bigger breakers/piping, and so on, wanted for them.  Immersion cooling is fascinating and has been mentioned within the trade for fairly a while; proper now, it isn’t as prevalent and never getting used a lot, however as densities enhance, it might turn out to be extra viable.  Onsite renewables are at all times an excellent thought on any undertaking, knowledge middle or not, however once more, the fee, ROI, viability of the location, consideration of the local weather, and so on., all have to be thought-about when deploying and deciding on which kind of renewable and the way a lot needs to be put in.

Thanks for the good interview, readers who want to study extra ought to go to PAE Engineers.