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So far, producing smart special parts in small quantities has been complex and expensive, because the downstream work steps focus specifically on the respective component. Now, igus produces intelligent wear parts in just a single work step. They apply a sensor layer to areas of the component that will undergo stress. Multi-material printing creates a wear-resistant component with integrated sensors. The process enables cost-saving predictive maintenance, even for special parts, as the component reports the need for replacement well in advance of failure. It also detects overload and immediately stops the application to prevent further damage.