Igus Debuts World’s First ESD-certified Dress Pack

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Igus Debuts World’s First ESD-certified Dress Pack

Igus Debuts World’s First ESD-certified Dress Pack

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Aug 30,25

Complete triflex ESD system from igus protects electronic components from electrostatic discharge - customers have been using basic systems successfully for over 15

Igus Debuts World’s First ESD-certified Dress Pack

Igus has launched triflex TRE ESD, the world's first ready-to-connect dress pack for industrial robots that is now ESD-certified, including all connection elements. The solution tested by Fraunhofer IPA significantly reduces design effort and increases safety in sensitive production areas such as microelectronics, the semiconductor industry or in the component production of battery systems. The system was seen for the first time at automatica 2025 in Munich.

Problems in the production line for miniature cameras: an industrial robot picks up a camera module from the conveyor belt to place it on a test platform. A tiny discharge spark flies across, invisible to the human eye. The module is destroyed. These electrostatic discharges (ESD) are repeated until operators finally find the culprit: a clamp with which the dress pack is attached to the industrial robot.

Igus closes a safety gap with triflex ESD

"Until now, no ESD-certified system covered both the energy chain and all connections in the critical area,” said Matthias Meyer, Head of Business Unit triflex e-chains and Robotics at igus. "Many users therefore realised their own connections. In addition to a high level of design effort, this also repeatedly led to errors that ultimately caused electrostatic discharges during production." To solve this problem, igus is now launching triflex TRE ESD. "This is the world's first ready-to-connect dress pack that is ESD-capable."

The Fraunhofer Institute for Manufacturing Engineering and Automation (IPA) has tested and certified the system for discharge capability - from the chain to the tension clamp to the strain relief. "Special coatings and dissipative materials guarantee that all components reliably dissipate electrostatic charges," said Meyer. "Design engineers no longer have to worry about ESD hazards when working in safety zones."

Basic systems successfully been used for over 15 years

The trifle ESD consists of movable, round links made of the high-performance plastic igumid ESD. The energy chain contains energy and data cables as well as hydraulic hoses that lead from the base of the robot to its working tool. The standard RS retraction or fibre-rod system are based on the same retraction system: internal fibreglass rods.

They ensure automatic retraction or an unsupported length that prevents contact between robot and energy chain. They are completely enclosed by the dissipative triflex R energy chain so that any voltage that may occur can be dissipated immediately. The chain is also available as a closed TRC ESD system, which has dry cleanroom certification (ISO Classes 4 and 5) from Fraunhofer IPA. "Both systems can be adapted to all common robot types and manufacturers. Their standard versions have been successfully used for over 15 years in customer environments," stated Meyer. "The additional ESD certification for energy chains and all connections in critical areas now offers our customers even more safety."

Igus GmbH specialises in the development and production of motion plastics — high-performance, lubrication-free polymers designed to improve technology and reduce costs in moving applications. The company is a global market leader in energy supply systems, highly flexible cables, plain and linear bearings, and lead screw technology made from tribo-polymers.

Headquartered in Cologne, Germany, igus is a family-run business with a presence in 33 countries and a workforce of around 5,200 employees worldwide. In 2024, the company reported a turnover of €1.105 billion. Its extensive research, conducted in the industry’s largest test laboratories, continually drives innovation and enhances safety for customers. igus also offers a portfolio of 245,000 stock items, with service life calculations available online.

In recent years, igus has diversified through the creation of internal start-ups, including ventures in ball bearings, robotic drives, 3D printing, the RBTX platform for lean robotics, and intelligent “smart plastics” tailored for Industry 4.0.

Sustainability remains a priority, with key initiatives such as the chainge recycling programme for used e-chains and investment in enterprises that convert plastic waste into oil — both significant steps in advancing circular economy practices.