A maintenance-free future for design engineers

Traditionally, this has meant relying on metal rails, ball bearings and repeated lubrication – tried-and-tested technologies that have served the industry well for decades.

However, as design priorities evolve, so too must the technologies on which we depend. Design engineers now face increasing pressure to reduce maintenance, improve sustainability and enhance system reliability – all while minimising cost. As a result, polymer-based linear motion systems are fast becoming the preferred solution.

The hidden costs of traditional linear systems
Steel-based linear guides and recirculating ball bearings are robust, but they come with a set of challenges that are often overlooked during the design phase. Lubrication is a major concern. Without regular greasing, metal components wear quickly, leading to increased friction, noise, and eventual failure. This maintenance requirement not only adds cost but also introduces downtime, stalling production.

In critical applications, such as cleanrooms or food processing, lubricants pose a contamination risk. Designers must implement complex sealing systems or schedule frequent cleaning, both of which increase complexity and cost. Additionally, metal components are heavy and prone to corrosion, especially in outdoor or washdown environments.

These limitations have led many engineers to question old methods and speculate that there must be a more sensible alternative.

Read the full article in DPA's October 2025 issue