238 chainflex cables receive certificate for use in dry cleanrooms

igus is the first supplier to qualify its halogen-free e-chain TPE cables for IPA dry cleanroom Classes 4 and 5

Around the world, the number of dry cleanrooms is increasing. The main focus is on automating the systems to ensure fast and cost-effective production. In addition to its certified energy chains suitable for dry cleanrooms, igus has now also had its halogen-free chainflex TPE cables successfully certified by the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA) in accordance with dry cleanroom Classes 4 and 5. This provides customers in highly automated battery production with energy management solutions with a reliable guaranteed service life of up to four years.

Clean production conditions play an essential role in the manufacture of lithium-ion batteries. Moisture, dust and particle emissions can lead to serious quality impairments and shorten the products' service life. As a result, there is an increasing demand for dry cleanrooms in which the relative humidity is typically below one per cent or in the range of a few ppm water content to protect hygroscopic materials, such as electrolytes in battery cells, from chemical reactions. However, not all machine components can withstand such difficult environmental conditions. "A lot of components are susceptible to wear due to the dry air, so they have to be replaced within a very short time," says Kira Weller, Product Manager e-chains and Cleanroom Expert at igus. Energy management solutions are essential for reliable energy and data transmission in dry cleanrooms. "To ensure that our cable guide systems meet the requirements of the dry environment, we are working together with the Fraunhofer IPA to develop and certify our motion plastics for use in dry cleanrooms," says Weller. This now also includes 238 chainflex cables. "They are our high-end TPE cables that have been specifically developed and tested for use in energy chains. The range includes control, bus, motor, robot, servo and measuring system cables," explains Rainer Rössel, Head of Business Unit chainflex Cables at igus. The cables were first extensively tested in the company's own 5,500-square-metre laboratory in Cologne before being awarded the two highest classes, 4 and 5, for dry cleanrooms following long-term tests at the Fraunhofer IPA. The certification guarantees low particulate emissions even under long-term stress as well as reliable material resistance in dry rooms, which are essential prerequisites for modern automation solutions in battery production.

Issuing the certificates together with Fraunhofer IPA

"The collaboration with Fraunhofer IPA gives our customers the certainty that our solutions work reliably even under the most stringent conditions," says Rössel. The specifically developed halogen-free TPE plastic outer ensures maximum cleanliness and durability of the cables. In addition, igus provides a four-year guarantee on all its products with a service life calculation. What makes it special is that the TPE cables are catalogue parts that can be ordered from stock, starting at one metre and without cutting charges. igus also waives minimum quantity surcharges and packaging costs. In addition to chainflex cables, the certified igus portfolio includes other products for dry cleanrooms. These include the energy chains in the series E6, e-skin soft, e-skin flat and easy chain E14. They have also been certified for cleanroom Class 4 and offer ideal solutions for applications in battery production, semiconductor manufacturing and other sensitive industrial sectors where cleanliness and durability are crucial.

Australian Manufacturing Week 2026 is set to be a cornerstone event for the nation’s industrial sector, bringing together manufacturers, engineers, and technology leaders to explore the future of production. Held annually, the exhibition provides a platform for showcasing cutting-edge machinery, tools, and digital systems that are transforming how goods are designed and produced. In 2026, the event is expected to place a strong emphasis on competitiveness, resilience, and sustainability within Australian manufacturing.

A key theme throughout Australian Manufacturing Week 2026 will be automation and its growing role in modern industry. From robotic assembly lines to autonomous material handling and AI-driven quality control, automation technologies are reshaping factories to be faster, safer, and more efficient. Exhibitors will demonstrate how integrating automated systems can reduce costs, improve precision, and address workforce shortages, while seminars will explore how businesses of all sizes can adopt these solutions effectively.

Dates: May 12-14

Venue: Brisbane Exhibition Centre

Stand No: 2224

Understanding utilisation and extending service life with the new “utilisation radar” analysis tool

WITTENSTEIN alpha presents a new feature of the Health Index gearbox analysis tool: the “utilisation radar”. This Smart Service analysis tool delivers information about critical operating states in WITTENSTEIN alpha gearboxes with cynapse^® functionality – that is, with integrated temperature and acceleration sensors, a logic and memory unit and an IO-Link data interface. The purpose of the utilisation radar is to determine the current total utilisation of a gearbox and to ensure it achieves its service life, or to extend this, by comparing the findings with individual limit values.

The analysis tool can therefore help to minimise failures, downtimes and maintenance costs for drive trains. For machine manufacturers, it opens up a wealth of opportunities in digital business models, for example, in the monitoring, servicing and repair of drive axles.

The analysis tool forms part of WITTENSTEIN alpha’s cynapse^® Analyse portfolio of Smart Services and will in future be offered for all the company’s gearboxes with cynapse^® functionality.

Operating states relevant to service life are now “on the radar”

The utilization radar delivers information about operating states with excessive levels of stress and the resulting negative effects on the service life of gearboxes with cynapse^®. The new feature is therefore of particular interest for machines with varying load profiles, high-availability systems in continuous operation, applications with high dynamics and use scenarios involving gearboxes that are hard to access or incur high maintenance costs for other reasons. The smart analysis tool and its data-based gearbox analysis therefore offer benefits to both machine manufacturers and operators.

Digital twin: Using analytical data in connected data spaces

The data from the cynapse^® Analyze is ideal for use in smart digital services aimed at monitoring the condition of gearboxes and drive trains. WITTENSTEIN is currently working on a research project to draw up standards regulating how data like this can be used jointly by different participants. The aim is to provide a uniform technical and legal framework in future for the use of this data in smart data spaces. The digital twin, which WITTENSTEIN alpha generates for every gearbox and offers to its customers, is a vital element that standardises and manages this data and makes it available.

cynapse^® Analyse by WITTENSTEIN alpha: a growing portfolio of digital analysis tools for smart gearboxes

In the interests of drive train digitalisation, WITTENSTEIN alpha offers a range of complementar and ever more sophisticated smart services for gearboxes with cynapse^® functionality. As the first building block, we have the basic cynapse^® Connect Smart Service for integrating and routing data. This includes both data provided by Cynapse and additional speed and torque data that can be made available by a servo drive or a PLC via OPC UA.

Expanding on this, the cynapse^® Monitor Smart Service allows easy visualisation and evaluation of smart gearbox data, including setting limit values and issuing alarms if these are exceeded. It provides insight into the operating behaviour of drive axles, so that critical operating states can be detected early on.

The cynapse^® Analyze is a continually growing portfolio of smart analysis tools. It includes the Health Index, which was introduced in 2024, and its utilisation radar feature, presented for the first time at SPS 2025. These analysis tools use data from the cynapse^® Connect and enable the operating behaviour of gearboxes and drive axles to be examined and improved. This allows even more complex anomalies in the machine process or component behaviour to be detected at an early stage, even simultaneously at different locations in a machine. Leading machine manufacturers incorporate solutions based on cynapse^® Analyze in their range of digital services for all aspects of their installations.

Precise, Resource-Efficient and Process-Reliable – the New P1MW Contrast Sensors for Print Mark Recognition in Series Applications

With the new P1MW series contrast sensors, the wenglor sensoric group is presenting a resource-efficient solution for standardized print mark recognition. With clearly structured functions, the sensors can be seamlessly integrated into existing processes without any integration effort. The highly visible white light and precise monochrome evaluation ensure reliable contrast detection with a wide range of colors. Thanks to the integrated jump detection and dynamic teach, the P1MW sensors are particularly robust against process-related deviations. They deliver stable and precise results even with misalignments, different color combinations or changed brand colors – ideal for high volumes in series production. 

Contrast marks are used in many industries to ensure consistent product quality of packaging material. The contrast marks applied to the materials control a wide range of processes, such as sealing, cutting, folding or gluing. Reliable recognition of print marks is critical for keeping operations running smoothly. The requirements for contrast sensors are varied: In addition to limited mounting space and high belt speeds, process-related deviations, such as misalignments or changed brand colors, also impair process reliability. wenglor’s new P1MW series contrast sensors are ready for use in just a few steps and immediately ensure stable processes in series production. The sensors switch reliably even when the mark changes color or when different materials are used. Thanks to the integrated jump detection, signal changes in the contrast curve are detected and marks are reliably detected even with changing batches and applications. The compact M design makes it the ideal choice for tight installation situations.

Dynamic Teach and Precise Light Spot
The P1MW sensors learn during operation. Dynamic teach simplifies initial startup and ensures maximum efficiency in the series production process during setup and adjustment. The small, homogeneous light spot enables reliable detection of even the smallest marks. The highly visible white light and monochrome evaluation ensure optimal contrast values even with challenging color combinations. An RGB light provides instant feedback on sensor status for quick diagnostics directly on the device. IO-Link 1.1 can be used to read and write process data, identify the sensor, read out extensive status messages and duplicate parameter data. The free wTeach2 software provides an overview of all data and settings.

 
The Highlights at a Glance:

• Precise and economical solution for series processes
• Process reliability thanks to jump detection
• Seamless initial startup thanks to dynamic teach
• Small, homogeneous light spot for detecting even the smallest marks
• Compact M design with dimensions of 54.5 × 27 × 16 mm
• IO-Link 1.1
• RGB status indicator

Intuitive operating concept with just one button

igus sets a new standard with the first online tool for the automatic design of Clean Cables

New e-skin flat configurator allows for quick design of certified cleanroom cable guide systems, including technical drawing and STEP file

Cleanrooms for the production of microchips and semiconductors are characterised across the globe by the absence of particles and limited space. To safely guide cables under these conditions, igus has developed the e-skin flat. The new e-skin flat configurator now allows for the fast and automated design of flat cable guide systems in cleanrooms. This reduces the previously manual effort to just a few minutes. Users can configure a complete system, have it filled automatically and then immediately download a technical drawing and parts list. With the e-skin flat, which is suitable for dry cleanrooms, igus has now also received the "Best of Industry Award 2025" in the category battery development and production.

The design of a cable guide system for cleanrooms, also referred to as Clean Cable, is complex: it is necessary to take numerous requirements into account, select suitable cables and create technical drawings. This process requires expert knowledge and has so far involved a lot of time and manual effort. This is exactly where igus comes into play with the new e-skin flat configurator. Users can design a flat cable guide system that is suitable for their cleanroom in just a few minutes. "The online tool is the first of its kind for configuring cable guide systems for cleanrooms. It leads users step by step through the design of their system, checks the feasibility and immediately provides all relevant data," explains Kira Weller, Product Manager e-chains and cleanroom expert at igus. "This ensures planning security without waiting times or time-consuming coordination." The e-skin flat provides users with a clean, flat and abrasion-resistant complete system made of high-performance plastic. Thanks to easy-to-open chamber systems, cables and hoses can be quickly inserted and replaced during maintenance. As it complies with EN ISO Class 1 according to DIN 14644-1, the Clean Cable also has the highest cleanroom classification.

Automatic filling for optimum results

How to configure the e-skin flat with the online tool: in the first step, the user enters the required application parameters such as speed, acceleration and travel. In addition, environmental parameters, limited installation space or an offset centre-fixed system can also be specified. In the next step, the user selects the cable. The tool offers access to the large chainflex cable pool from igus as well as readycables already harnessed with connectors, prioritising suitable cables for the e-skin flat system. Users can also add their own cables. This is followed by automatic filling. An algorithm integrated into the online tool uses the product data stored in the system and the specified customer parameters and recommends the best possible solution for the application based on previously defined rules. The tool also signals if a configuration cannot be realised. Manual adjustments can be made at any time in the configurator.

From configuration to quotation request in just a few clicks

All relevant data is immediately available for download on the results page - from technical drawing to parts list to installation instructions. Customers can also download an additional STEP file. If the user is satisfied with the design, he/she can request a corresponding quotation and the igus experts carry out a final check of the configured system. "We wanted to make the configuration process for cleanroom cable guide systems as simple as possible," says Weller. "With the new e-skin flat configurator, we are providing our customers with a complete package that allows them to continue design work immediately. Thanks to intelligent automation, we are able to significantly reduce the manual workload for both our customers and ourselves and maximise planning reliability." e-skin flat has now also received the annual "Best of Industry Award 2025" from the trade magazine MM MaschinenMarkt in the category battery development and production. "We are delighted to receive this award, which is also an incentive for us to continue our development in this area," emphasises Weller.

PFAS-tested: new dryspin® lead screw nut for quick replacement

Universal lead screw nut with flange from igus allows for a quick 1:1 conversion without design adjustments

Design engineers who want to replace the lead screw nuts of lead screw drives with PFAS-tested alternatives often face a dilemma: there are hardly any versions that are free of the controversial chemical, meaning that expensive adaptations would be necessary. igus is changing this with a new PTFE-free and PFAS-tested universal flange lead screw nut made of iglidur high-performance plastic. It allows a quick 1:1 conversion and promises an above-average service life thanks to a special thread geometry.

A design engineer of a packaging machine has been assigned a new task: replacing all plastic components with versions that do not use the chemical group PFAS. They might be more strictly regulated in future as they represent a potential burden for people and nature. The conversion is intended to ensure future legal certainty. But the devil is in the details. The design engineer cannot find an alternative for the small plastic nuts of a lead screw drive. There are hardly any PFAS-tested lead screw drives on the market. And the few that are available have a flange with different connection dimensions for the nut mount. "To solve this dilemma, we have developed a universal lead screw nut with flange that is PTFE-free and has been tested for the 96 most critical PFAS compounds," says Thorben Hendricks, Head of dryspin® Lead Screw Technology at igus. "The injection-moulded component has a flexible hole pattern with closed and open holes, which allows for quick 1:1 replacement without requiring design adjustments." The universal lead screw nut with flange from the dryspin series is now available with thread diameters of 6.35mm, 8mm and 10 mm.

Longer service life thanks to special thread geometry

Another special feature is the threads' flexibility: igus initially manufactures blanks for the universal lead screw nuts with flange in an injection-moulding process from a material called iglidur JPF. Different thread types can be

inserted into these blanks according to customer requirements. "Our patented dryspin thread is becoming increasingly popular in the industry," explains Hendricks. The reason: in contrast to classic sliding threads, where the lead screw and nut have symmetrical profiles, the dryspin nut's thread teeth are enlarged by a factor of up to 1.3. "Thanks to the asymmetry, we were able to increase the service life by around 30% compared to conventional trapezoidal threads, as tests in our in-house laboratory have shown," emphasises Hendricks.

PTFE coating of the lead screw no longer required

The new universal lead screw nuts with flange also allow for dry operation. Microscopic solid lubricants are integrated into the iglidur JPF material, which permit the material to slide. The advantage: external lubrication is no longer required. This reduces the system's maintenance requirements and susceptibility to dirt. "Another benefit of low-friction dry operation is that the lead screws no longer require PTFE sliding layers. This provides our customers with complete system solutions that are PTFE-free and PFAS-tested," says Hendricks.

Space-saving, abrasion-resistant and dissipative: compact e-skin soft ESD for cleanrooms

Dissipative energy chain from igus with self-supporting function makes space-consuming shielding superfluous

The demand for electric cars and the use of AI are growing, so that more and more lithium-ion batteries and microchips are required. As these technologies have to deliver performance that continues to increase, they are also becoming more sensitive and place high demands on production environments. With the e-skin soft ESD, igus is now launching a new energy chain for cleanrooms that is both abrasion-resistant and dissipative. It is a game changer for design engineers as it allows for significantly more flexibility and saves space in energy supply systems.

Tiny electrostatic discharges (ESD) are invisible to the eye, but can damage sensitive products in semiconductor and electronics production. It is therefore important that all machine components used in the vicinity of these products have ESD protection. However, this is not a matter of course when guiding power and data cables as they are generally not dissipative. "Many design engineers realise special kinds of shielding, but this wastes valuable space in cleanrooms," says Kira Weller, Product Manager for e-chains and Cleanroom Expert at igus. An equally impractical alternative is to keep a large distance from the product, which can also lead to space problems. To solve this dilemma, igus has developed a new version of the cleanroom-compatible e-skin soft energy chain: the e-skin soft ESD, a compact e-chain that is both abrasion-resistant and dissipative thanks to additives in the material. Electrostatic charges can be dissipated via the mounting brackets, similar to a lightning conductor. Says Weller: "The new energy chain is a game changer for design engineers as it can be used close to the product without additional shielding."

Space-saving e-chain allows for tight bend radii

The e-skin soft ESD has a compact design and requires very little installation space. It consists of an upper and a lower shell, which form a closed pipe housing that securely encloses pipes, cables or media guides. It is made from our own high-performance plastic, which allows for tight bend radii of 55mm. The inner height varies between 20mm, 24mm, 28mm and 40mm depending on the version, the inner width between 33mm, 48mm, 68mm and 85mm. Another thing that makes it special: thanks to its oval geometry and defined stiffness, the e-skin soft ESD can also realise unsupported lengths, unlike conventional corrugated hoses. This makes a guide superfluous. In addition, the energy chain is particularly durable and achieves a service life of more than 20 million double strokes.

On the way to the highest level of cleanliness, ISO Class 1

The e-skin soft ESD fulfils the strictest cleanroom requirements. "The high-performance plastic is extremely abrasion-resistant, so that no particles are produced during operation, even during fast movements," emphasises Weller. Particles from the cables cannot escape either as the upper and lower shells can be joined together to form a closed pipe using the zip principle. "This guarantees both cleanroom suitability and fast filling and maintenance of the cables," says Kira Weller. The new energy chain has already passed tests in the in-house cleanroom laboratory in Cologne, which was realised together with the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA) with very good results. The official certification will come into effect in the coming weeks.

https://www.igus.eu/energy-chain/news/e-skin-soft-esd

Powerful connections for every challenge

When machines communicate with each other, robots perform precise movements or wind turbines feed electricity into the grid, it is often powerful connections in the background that make everything possible: such as EPIC® connectors from LAPP.

LAPP, a leading provider of integrated solutions in cable and connection technology, from high-current solutions to innovative push-pull systems.

Applications with extreme currents – EPIC® POWERLOCK

With a current carrying capacity of up to 660 A, the EPIC® POWERLOCK is one of the most powerful single-pole connectors in its segment. This system was recently redesigned by LAPP. The round connector is now available in the new POWERLOCK version, which significantly simplifies assembly and unlocking.

The core feature is a newly developed mechanism with a fully integrated slider that allows release without. This makes handling easier and prevents improper disconnection of the plug connection.

The contacts inside have also been redesigned: instead of different variants – depending on the conductor cross-section, POWERLOCK uses a single cone-shaped axial screw contact that automatically fans out the strands when inserted. This allows diameters from 35 to 240 mm² to be reliably connected. The combination of mechanical and colour codiur coding minimises the risk of incorrect connections and enables clear assignment of the conductors.

With its high current-carrying capacity, IP-protected design, and reliable locking mechanism, EPIC® POWERLOCK is particularly suitable for industrial distribution systems, test benches, and mobile power supply solutions.

Resilient solutions for powerful motors – EPIC® M23 Power with Quickflex technology

With the EPIC® M23 Power Quickflex, LAPP presents a circular connector that combines high electrical resilience with an innovative tool-free locking system. This connector sets new standards in connection technology for servo motors, automation technology, and demanding industrial applications.

Thanks to integrated Quickflex technology, the EPIC® M23 Power offers maximum flexibility. Variable pole configurations and modular interchangeable inserts enable easy adaptation to different power requirements and device configurations. This not only facilitates quick conversion in the field, but also offers new possibilities in system planning – especially for applications that require high current carrying capacity in limited space.

The robust design of the connector, combined with its high vibration and temperature resistance, makes it ideal for drive and automation solutions, robotics systems, and mobile machines.

For lightning-fast communication – EPIC® ClickConnect

With the new EPIC® ClickConnect technology, LAPP offers a compelling solution for the increasing demands and accelerated installation and maintenance processes in industrial production. The push-pull solution for M12 patch cords and cord sets relies on a completely tool-free locking system and opens up a new dimension in efficiency, safety, and reliability for users in automation, mechanical engineering, and industrial communication.

The focus is on tool-free locking based on a mechanical locking mechanism. The connection locks automatically with a simple push-fit. The resulting haptic and acoustic feedback ensures a reproducibly secure connection. Unlocking is just as easy by pulling on the integrated release element. The system thus significantly reduces installation times and is optimised for use in compact installation environments where conventional screw or clamping mechanisms are only accessible to a limited extent.

Thanks to its ease of use and minimised susceptibility to errors, EPIC® ClickConnect is particularly suitable for applications where maintenance intervals are short and production downtimes are critical.

Bundled expertise in the field of connectors

With the new products presented, LAPP underscores its role as a leading supplier of connection technology for industry. The EPIC® series stands for maximum reliability, versatile application possibilities, and advanced technology—properties that are indispensable in modern automation.

Treotham Automation is the official supplier of LAPP products. For more information, please contact your nearest treotham office on 1300 65 75 64 

Enhanced Detection with Blue Light Technology
Wenglor introduces its latest wintec sensors equipped with blue laser light. Because blue light has a shorter wavelength, it penetrates surfaces less deeply than conventional red light. This results in exceptionally stable detection performance—even on challenging materials such as dark, glossy, organic, or (semi-)transparent surfaces. Combined with Wenglor’s proven Dynamic Sensitivity technology, the new wintec generation delivers outstanding precision and reliability, making it an ideal choice for demanding automation applications.

Develop AI Models with Ease Using the New AI Lab
In the field of machine vision, Wenglor presents the new AI Lab—an advanced cloud-based platform designed for streamlined data management and efficient AI model training. The platform integrates seamlessly with Wenglor’s uniVision 3 software, which handles image acquisition and executes AI models directly on machine vision systems. The weHub software ensures smooth data exchange between uniVision 3 and the AI Lab, automatically managing the upload of image datasets and the retrieval of trained models. This “AI Loop” workflow provides users with an intuitive, end-to-end process for fast, user-friendly AI model development.

Additional Innovations and Trusted Solutions
Wenglor also expands its portfolio with several new and enhanced products, including:

• P1MW contrast sensors for precise print-mark detection in high-volume, series applications
• IO-Link system solutions that improve connectivity and simplify integration
• Reflex sensors with time-of-flight technology for reliable long-distance object detection
• P1PC laser distance sensors using triangulation to meet a wide range of measurement requirements

The P1PC family delivers consistent, reproducible measurement results, ensuring high process reliability—even in demanding industrial environments and high-throughput applications.