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Service life calculation thanks to the test laboratory

iglidur 3D-printed components on the test rig

3D printing polymers that, in moving parts, last up to 80 times as long as normal plastics and in some applications are more durable than metal.

Is that a pipe dream? No, those are the clear statistics provided by testing in our test laboratory and confirmed by our customers. Calculated, tested, proven: each statement about the service life of iglidur plastics for additive manufacturing is based on comparisons that have been performed many times. Their evaluation is also the data basis for our Long Life Calculator - which you can use to calculate the expected service life of your printed components in just a few clicks.

Upload your CAD model here and calculate the service life of your individual componentDetermine the service life specifically for gears here

You can find these wear tests on this page:

Linear bearing with arrows showing the wear test.

Comparison of 3D printed linear bearings

Less wear than ABS by a factor of 33

To the linear wear test
Plain bearing with arrows pointing left and right to show movement direction and wear test.

3D printed bushing in short linear stroke testing

More than 300 times the service life of ABS

To the linear short-stroke test
3D-printed bushing in a wear test with arrows for rotation direction.

3D printed plain bearings in the pivot test

Up to 50 times the abrasion resistance of PA12

To the pivot tests
3D-printed threaded nut in a wear test with orange wear marks.

Printed drive thread nuts tested

Up to 18 times the durability of ABS

To the drive nut test
Idler pulley for the 3D printing wear test.

Coefficient of friction and service life test for rotating bearings

High service life with iglidur i3 - failure with ABS

To the rotation tests
Two gears in a wear test for 3D printing.

3D printed gears in testing

Up to 80% more abrasion-resistant than ordinary plastics

To the gear tests

Wear test: Linear long stroke

3D printing materials in the test: Wear-resistant plastic iglidur i3 beats ABS material by a factor of 33

Test parameters:

  • Surface pressure: 0.11MPa
  • Surface speed: 0.34m/s
  • Stroke: 370mm
  • Running time: 3 weeks

Shaft materials: aluminium hc

Linear guide in a wear test on a test machine.
Linear guide in a wear test on a test machine.

Y-axis: Wear rate [μm/km]

X-axis: Materials in the test

1. ABS (FDM 3D printing)
2. iglidur i180 (FDM 3D printing)
3. iglidur i3 (SLS 3D printing)
4. iglidur J (injection moulding)

Bar chart with four values: 13.3, 0.8, 0.4, and 0.2.
Bar chart with four values: 13.3, 0.8, 0.4, and 0.2.

Test result:
The long-stroke test shows 15 times lower wear values for iglidur i180 (FDM) and even 33 times lower values for iglidur i3 (SLS). Due to the very good tribological specifications, the wear-resistant iglidur materials are ideal for long-stroke applications, e.g. XY linear robots for pick & place applications or plain bearings and glide bars in the 3D printer.

Wear test of long-stroke linear products with four states of the internal gearing.
Wear test of long-stroke linear products with four states of the internal gearing.

Wear test: Linear short stroke

Tribological specifications of plain bearings from 3D printing almost identical to injection-moulded bearings

Determine the service life of 3D-printed plain bearings in your application. Just enter the required parameters in the free Long Life Calculator for plain bearings and have the service life of the bearing calculated. ⯈ To the Long Life Calculator

Test parameters:

  • Surface pressure: 1MPa
  • Surface speed: 0.3m/s
  • Stroke: 5mm
  • Running time: 1 week

Shaft materials:

■ CF53 / AISI 1055: Hardened steel
■ 304 SS / AISI 304: Stainless steel

Linear wear test system with short stroke and several carriages on a test rig.
Linear wear test system with short stroke and several carriages on a test rig.

Y-axis: Wear rate [μm/km]

X-axis: Materials in the test

1. ABS (FDM 3D printing)
2. iglidur J260 (FDM 3D printing)
3. iglidur J260 (injection moulding)

Bearing wear comparison: the 3D-printed bearing shows more wear than the injection-moulded bearing.
Bearing wear comparison: the 3D-printed bearing shows more wear than the injection-moulded bearing.

Test result:
The plain bearing made of wear-resistant plastic iglidur J260 has similarly good wear rates, regardless of whether it was manufactured in 3D printing or injection moulding. In the test, iglidur J260 injection moulded plain bearings and 3D-printed bearings were tested with the same load and surface speed. 
This test also shows that the friction coefficients and abrasive wear of our iglidur 3D printing materials are many times lower than those of standard ABS materials thanks to the tribological specifications.

Three wear-tested plain bearings in black and beige, numbered 1 to 3.
Three wear-tested plain bearings in black and beige, numbered 1 to 3.

Bearings made of 3D-printed sliding plastics impress due to their significantly longer service life than bearings made from conventional 3D-printed plastics and their wear values that are at least as low as those of machined components.

Test parameters:

  • Surface pressure: 1MPa
  • Surface speed: 0.1m/s

Shaft materials:

■ CF53 / AISI 1055: Hardened steel
■ 304 SS / AISI 304: Stainless steel

Chart comparing bearing wear in 3D printing, injection moulding and turning under linear test conditions.
Chart comparing bearing wear in 3D printing, injection moulding and turning under linear test conditions.

X-axis: Materials in the test

1. iglidur i3 (SLS 3D printing)
2. iglidur i150 (FDM 3D printing)
3. iglidur i190 (FDM 3D printing)
4. PA12 (SLS 3D printing)
5. ABS (FDM 3D printing)
6. PA66 (injection moulding)
7. POM (machined)
8. PA66 (machined)

Wear test: Pivoting

Up to 50 times higher abrasion resistance thanks to iglidur plastic

How long will a 3D-printed iglidur bearing last in your application? Just enter the requirements and determine the service life online with our free Long Life Calculator for plain bearings: ⯈ To the Long Life Calculator

Test parameters:

  • Surface pressure: 20MPa
  • Surface speed: 0.01m/s
  • Pivoting angle: 60°
  • Running time: 4 weeks

Shaft materials: 304 SS

Wear test on a swiveling metal assembly with multiple support and clamping points.
Wear test on a swiveling metal assembly with multiple support and clamping points.

Y-axis: Wear rate [µm/km]

X-axis: Materials in the test

1. PA12 (SLS 3D printing)
2. PA12 + glass beads (SLS 3D printing)
3. iglidur i3 (SLS 3D printing)
4. iglidur W300 (injection moulding)

Bar chart of a wear test: bar 1 at 402.2, bar 2 at 209.2, bar 3 at 37.7, and bar 4 at 42.
Bar chart of a wear test: bar 1 at 402.2, bar 2 at 209.2, bar 3 at 37.7, and bar 4 at 42.

Test result:

In the pivot test, the tribological specifications of the iglidur materials lead to up to 50 times higher abrasion resistance compared to the standard 3D printing materials (e.g. PA12).

Four worn plain bearings compared after an oscillating wear test.
Four worn plain bearings compared after an oscillating wear test.

In the swivel test, bearings made of 3D-printed sliding polymers exhibit a service life several times that of other plastics, regardless of the manufacturing process.

Test parameters:

  • Surface pressure: 2MPa
  • Surface speed: 0.01m/s
  • Pivoting angle 60°

Shaft materials:

■ CF53 / AISI 1055: Hardened steel
■ 304 SS / AISI 304: Stainless steel

Bar chart comparing bearing wear in 3D printing, injection molding, and turning.
Bar chart comparing bearing wear in 3D printing, injection molding, and turning.

X-axis: Materials in the test

1. iglidur i3 (SLS 3D printing)
2. iglidur i150 (FDM 3D printing)
3. iglidur i190 (FDM 3D printing)
4. PA12 (SLS 3D printing)
5. ABS (FDM 3D printing)
6. PA66 (injection moulding)
7. POM (machined)
8. PA66 (machined)

Wear test: Pivoting heavy load

Comparable tribological specifications for printed and injection moulded bearings

Determine the exact service life of a 3D-printed bearing made of iglidur in your application. Just enter the required parameters in the free Long Life Calculator for plain bearings and calculate the service life online: ⯈ To the Long Life Calculator

Test parameters:

  • Surface pressure: 10, 20 and 45MPa
  • Surface speed: 0.01m/s
  • Pivoting angle: 60°
  • Running time: 1 week

In the test, plain bearings with a diameter and length of 20mm were tested, i.e. a load of 1,800kg was applied to the 3D-printed plain bearing.

Oscillating load test with a metal joint and pressure gauge on a test rig.
Oscillating load test with a metal joint and pressure gauge on a test rig.

Y-axis: Wear rate [µm/km]

X-axis: Materials in the test

1. iglidur i3 (SLS 3D printing)
2. iglidur i180 (FDM 3D printing)
3. iglidur G (injection moulding)
4. iglidur W300 (injection moulding)

Diagram comparing wear of plain bearings at different surface pressures.
Diagram comparing wear of plain bearings at different surface pressures.

Test result:
This heavy load test shows that 3D-printed plain bearings (SLS process) can be subjected to a surface pressure of up to 45MPa. The abrasive wear is just as good as with plain bearings from injection moulding. Use in high-load applications is therefore possible.

Four wear samples of plain bearings in different material colors, numbered 1 to 4.
Four wear samples of plain bearings in different material colors, numbered 1 to 4.

Wear test: Swivelling under water

Comparison of the wear rates of iglidur materials for 3D printing and injection moulding in use under water

Test parameters:

  • Surface pressure: 1 and 2MPa
  • Surface speed: 0.01m/s
  • Temperature: 23°C

Shaft material: 304SS

X-axis: Materials in the test

1. iglidur i3 (SLS 3D printing)
2. iglidur i8-ESD (SLS 3D printing)
3. iglidur J (injection moulding)
4. iglidur UW (injection moulding)
5. iglidur UW160 (injection moulding)

Y-axis: Wear rate [µm/km]

Comparison of wear of iglidur materials for 3D printing and injection moulding in an underwater test with two loads.
Comparison of wear of iglidur materials for 3D printing and injection moulding in an underwater test with two loads.

Test result:
This pivot test under water shows that 3D-printed plain bearings made of the [electrostatically dissipative SLS material iglidur i8-ESD](/de-de/website/3d-druck/material/#ESD-taugliche Werkstoffe "fb73e0e2-1130-4a71-97b5-5c0928734375") have a particularly high service life and the material is therefore just as suitable for such applications as the injection moulding materials iglidur UW and UW160, which were specially developed for use under water.
iglidur J is a frequently used igus material in a dry environment, but is not so well suited for use under water due to its rather high wear rate.

Wear test: Drive nut

iglidur materials in 3D printing: Wear-resistant plastics more durable by a factor of 6 to 18 compared to standard materials

Test parameters:

  • Torque: 129Nm
  • Stroke: 370mm
  • Speed (spindle speed): 290rpm
  • Running time: 2 weeks
Drive nuts on a wear-test rig.
Drive nuts on a wear-test rig.

Y = Wear rate [µm/km]

X-axis: Materials in the test

1. ABS (FDM 3D printing)
2. iglidur i180 (FDM 3D printing)
3. iglidur J260 (FDM 3D printing)
4. iglidur i3 (SLS 3D printing)
5. iglidur J (injection moulding)

Comparison of wear rate of 3D-printed and injection-moulded thread nuts: bar chart with five values.
Comparison of wear rate of 3D-printed and injection-moulded thread nuts: bar chart with five values.

Test result:
In this test, the wear resistance of igus 3D printing materials compared to conventional materials, depending on the 3D printing material and process, is 6 to 18 times
higher. Producing drive nuts using 3D printing offers cost advantages, especially for small quantities, as the thread can be produced directly in 3D printing and no expensive tool is required to cut the thread. All that is required is that the thread is designed in the model.

Wear test of drive nuts with five numbered samples in different colors.
Wear test of drive nuts with five numbered samples in different colors.

Friction coefficient test: Rotating

Wear-resistant plastic iglidur and standard ABS material in comparison - lower coefficient of friction with iglidur

Wear-resistant plastics and tribological specifications are helpful in the design of motors or drive forces, since with half the friction only half the drive force is required. With our free Long Life Calculator for plain bearings, you can determine how long a 3D-printed plain bearing made of iglidur will last in your application by specifying your requirements.

Test parameters:

  • Surface pressure: 1MPa
  • Surface speed: 0.1m/s

Shaft material: Cf53

Test setup with a rotating metal shaft in a machine.
Test setup with a rotating metal shaft in a machine.

Y = Coefficient of friction [-]
X = Running time [h]

1. PA12 (SLS 3D printing)
2. iglidur i3 (SLS 3D printing)

Graph with two lines: the black curve rises slightly and stays nearly stable, the orange curve drops and then levels off.
Graph with two lines: the black curve rises slightly and stays nearly stable, the orange curve drops and then levels off.

Test result:
The tribological specifications of iglidur i3 are better in the test by a factor of 2 than with the standard 3D printing materials. This is due to the fact that solid lubricants are integrated in iglidur materials, which reduce the friction values and significantly increase the wear resistance.

Three rotating plain bearing samples with different wear, numbered 1 to 3.
Three rotating plain bearing samples with different wear, numbered 1 to 3.

Wear test: Rotating

Wear values of iglidur 3D printing materials in comparison with common 3D printing plastics

How long does a 3D-printed bearing made of iglidur last in your application? Use our Long Life Calculator for plain bearings to precisely determine the service life by specifying the necessary requirements.

Test parameters:

  • Surface pressure: 20 MPa
  • Surface speed: 0.01 m/s

Shaft material: 304 SS

Test setup for rotation and wear with several sample cylinders.
Test setup for rotation and wear with several sample cylinders.

Y-axis: Wear rate [µm/km]

X-axis: Materials in the test

1. ABS (FDM 3D printing)
2. PA12 (SLS 3D printing)
3. iglidur i180 (FDM 3D printing)
4. iglidur J260 (FDM 3D printing)
5. iglidur i3 (SLS 3D printing)
6. iglidur W300 (injection moulding)

Simplified graph comparing bearing wear in a rotating test.
Simplified graph comparing bearing wear in a rotating test.

Test result:
The wear of printed plain bearings made from iglidur i180 is 89.5% lower than that of bearings made from the frequently used ABS plastic in the same process. The sintered bearing made of iglidur i3 proved to have 94.87% less wear than the sintered bearing made of PA12. Only the bearing made of the special filament iglidur J260 and the bearing manufactured in injection moulding from iglidur W300 exhibited better values.

Six 3D-printed bearing bushings, numbered 1 to 6, with different wear levels.
Six 3D-printed bearing bushings, numbered 1 to 6, with different wear levels.

In the rotation test, bearings made of 3D-printed sliding polymer perform much better than bearings made of regular plastics, regardless of the manufacturing process.

Test parameters:

  • Surface pressure: 1MPa
  • Surface speed: 0.3m/s

Shaft materials:

■ CF53 / AISI 1055: Hardened steel
■ 304 SS / AISI 304: Stainless steel

Comparison of wear rate of plain bearings with three manufacturing methods under rotating conditions.
Comparison of wear rate of plain bearings with three manufacturing methods under rotating conditions.

X-axis: Materials in the test

1. iglidur i3 (SLS 3D printing)
2. iglidur i190 (FDM 3D printing)
3. PA12 (SLS 3D printing)
4. ABS (FDM 3D printing)
5. PA66 (injection moulding)
6. POM (machined)
7. PA66 (machined)

Wear test: Rotating under water

Comparison of the wear rates of iglidur materials for 3D printing and injection moulding in use under water

Test parameters:

  • Surface pressure: 1 and 2MPa
  • Surface speed: 0.3m/s
  • Temperature: 23°C

Shaft material: 304SS

X-axis: Materials in the test

1. iglidur i3 (SLS 3D printing)
2. iglidur i8-ESD (SLS 3D printing)
3. iglidur J (injection moulding)
4. iglidur UW (injection moulding)
5. iglidur UW160 (injection moulding)

Y-axis: Wear rate [µm/km]

Comparison of iglidur material wear rates in an underwater rotating test.
Comparison of iglidur material wear rates in an underwater rotating test.

Test result:
The rotation test under water shows that 3D-printed plain bearings made of the [electrostatically dissipative SLS material iglidur i8-ESD](/de-de/website/3d-druck/material/#ESD-taugliche Werkstoffe "fb73e0e2-1130-4a71-97b5-5c0928734375") have a particularly high service life and the material is therefore just as suitable for such applications as the injection moulding materials iglidur UW and UW160, which were specially developed for use under water.
iglidur J is a frequently used igus material in a dry environment, but is not so well suited for use under water due to its rather high wear rate.

Test for UV and weather resistance

Comparison of the change in strength of iglidur materials for 3D printing and injection moulding

Test conditions:

  • ASTM G154 cycle: Simulation of weathering and UV light
  • Duration: 2,000 hours

X-axis: Materials in the test

1. iglidur i8-ESD (SLS 3D printing)
2. iglidur i3 (SLS 3D printing)
3. iglidur i6 (SLS 3D printing)
4. iglidur J (injection moulding)
5. iglidur G (injection moulding)

Y-axis: percentage change in strength

Bar chart comparing five material values after weathering and UV exposure.
Bar chart comparing five material values after weathering and UV exposure.

Test result: SLS materials are in no way inferior to injection moulding materials

After the bending test specimens were exposed to moisture and UV light for 2,000 hours in the test, it was shown that the iglidur materials for selective laser sintering exhibit a similar change in strength as the most frequently used injection moulding materials iglidur J and G. The SLS material iglidur i8-ESD is the most resistant to weathering and UV light. This test makes it clear that the iglidur 3D printing materials are in no way inferior to the injection moulding materials in terms of UV and weather resistance.

Gear test: Cycles until gear breaks

Test parameters:
Pivoting 1440°:
n = 64rpm
M = 2.25Nm
z = 30
m = 1
b = 6mm

Rack and pinion in a test setup for 3D printing.
Rack and pinion in a test setup for 3D printing.

In this test, a gear rack is driven with a gear and the number of cycles after which the gear breaks if measured. It can be seen that the iglidur gears produced by 3D printing or laser sintering last twice as long in the test as milled gears made of POM.

X-axis: Materials in the test

1. iglidur i3 (printed)
2. iglidur i8-ESD (printed)
3. POM (milled)
4. iglidur i6 (printed)
5. iglidur i190 (printed)
6. PLA (printed)
7. PETG (printed)
8. SLA

With the exception of the gear made of POM, the CAD models of all tested gears originate from the igus gear configurator.

Chart comparing the service life of gears made from iglidur and standard materials.
Chart comparing the service life of gears made from iglidur and standard materials.

Extremely long service life of worm gears with optimised sliding properties

Test parameters:

  • Torque: 4.9Nm
  • Speed: 12rpm
  • Mating partner: Anodised aluminium
  • Running time: 2 months

Evaluation:

► POM (milled): Total failure after 621,000 cycles
► iglidur i6 (sintered): Low wear after 1 million cycles

Low abrasive wear due to tribology plastics from the 3D printer

Wear is an important aspect for components in moving applications. Wear-resistant plastics such as our iglidur materials are the solution to minimise wear and increase the parts' service life. Their tribological specifications make iglidur materials perfect for all applications in which a good coefficient of friction and the very low wear are essential.

The igus test laboratory covers 3,800m². In an extensive series of experiments, igus is researching and developing new 3D printing materials for moving applications in the industry's largest test laboratory. All materials are tested for their tribological specifications in various test series to minimise wear and maintenance intervals. They are particularly low-friction and wear-resistant and ensure lubrication-free and low-maintenance operation.

iglidur plastics offer very good tribological specifications and therefore guarantee a longer service life for plastic components.

In our test laboratory, we continuously test the tribological specifications of 3D-printed parts in accordance with DIN ISO 7148-2. The test series included linear, pivoting and rotating movements on various shaft materials. With our iglidur J260 filament, the coefficient of friction and wear were low in all tests while the standard ABS material failed quickly in the rotating test on the stainless-steel shaft. The wear resistance of printed plain bearings made of iglidur special filament is similar in all test setups to that of classic iglidur injection-moulding components. Thanks to the wear-resistant plastic iglidur i3 and an optimised tooth shape, our 3D-printed gears achieve a longer service life than gears made of standard materials.

Consulting

I look forward to answering your questions

visnevksi
Andrei Visnevski

Regional Manager for Baltics

+372 588 73933Write e-mail

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