Polymer bearings improve efficiency in electrified systems by minimizing frictional losses, reducing maintenance demands, and enabling more compact, lightweight designs. Increasing electrification across transportation, robotics, aerospace, and industrial automation demands components that can sustain high performance in small spaces. In compact, high-speed electric systems, traditional metallic or lubricated bearings can increase drag, require more maintenance, and add unnecessary weight.
In this blog post, we discuss how PTFE plane bearings deliver measurable efficiency gains by reducing friction, eliminating external lubrication, and enhancing durability under demanding operating conditions.
The Role of Bearings in Electrified Systems
Bearings play a pivotal role in electrified systems, supporting rotating shafts, actuators, and linkages while minimizing friction and wear. Their role in maintaining high precision shaft alignment for rotor-stator clearance and impacting electromagnetic efficiency cannot be overstated.
Bearings have a significant impact on system efficiency. As far as energy loss pathways, polymer bearings offer reduced friction, generate less heat, and can avoid issues with lubrication drag when self-lubricating polymers are used. This understanding is crucial for designing high-efficiency electrified systems.
It’s important to remember that higher friction leads to a loss of energy, which manifests as heat generation. This can be critical to efficiency in many motor-driven applications. However, with the use of polymer bearings, particularly those made from PTFE, this energy loss can be significantly reduced, offering a promising future for your systems.
PTFE as a Bearing Material for High-Efficiency Electrified Systems
PTFE is an excellent choice as a material for plane bearings. It exhibits an exceptionally low coefficient of friction (both static and dynamic), operates over a broad temperature range that includes both cryogenic and high ranges (-200°C to +260°C), and is chemically inert to coolants, dielectric fluids, and environmental contaminants.
Related to its extremely low coefficient, there are other tribological advantages. For example, PTFE has a very low stick-slip tendency, even at low speeds or when oscillatory motion is involved. It is naturally self-lubricating, and that can be enhanced or tailored through the use of embedded solid lubricants or fillers.
PTFE also has excellent electrical insulation properties that prevent stray current corrosion. And its non-magnetic nature eliminates the potential of it causing EMI interference in sensitive electronic systems.
Optimized PTFE Formulations
Several different fillers and formulations for PTFE can enhance specific properties.
Glass-Filled PTFE
Glass-fileld PTFE possesses increased wear resistance under high-load, low-speed applications and also has improved dimensional stability for operations that involve thermal cycling.
Carbon-Filled PTFE
When filled with carbon fibers, PTFE will have a higher compressive strength and improved thermal conductivity for heat dissipation. This type of filled PTFE is also suitable for high PV (pressure × velocity) values in compact electric drive systems.
Bronze-Filled PTFE
Bronze-fileld PTFE has an enhanced load capacity but at the cost of slightly higher friction. Such trade-offs are often required for torque-heavy systems.
Graphite or MoS₂-Filled PTFE
This type of filled PTFE is optimized for dry-running, high-frequency reciprocation without lubrication.
Hybrid Composites
Hybrid composites are multi-filler systems that can achieve combined strength, low wear, and static dissipation.
How Polymer Bearings Improve Efficiency in Electrified Systems
Reduction of Frictional Losses
High-performance polymer bearings exhibit coefficients of friction as low as 0.05–0.15, versus 0.35–0.60 for bronze. This lower drag reduces torque demand in electric motors, extending battery life in EVs and robotics, increasing range, and allowing smaller battery packs without performance loss.
Thermal Efficiency
Less friction means less heat. Polymer bearings ease cooling system demands, enabling smaller, lighter thermal management components. Lower temperatures maintain dimensional stability under continuous duty, extending service life and preventing heat-related failures.
No External Lubrication Requirement
Self-lubricating polymers eliminate grease and oil, removing parasitic drag from lubricant shear in high-speed applications. In automation, this reduces maintenance, prevents contamination, and increases uptime by simplifying bearing service.
Design Considerations for Maximizing Bearing Efficiency
The table below discusses some of the key design considerations when seeking to maximize the efficiency of PTFE plane bearings.
| Design Factor | Key Parameters | Best Practices |
| Load and Speed Ratings | PV limits vary by PTFE formulation: Virgin PTFE ~1,000–3,000 psi·ft/min (continuous), Filled PTFE 4,000–10,000+ psi·ft/min (continuous). Intermittent operation allows higher PV. | Select formulation based on duty cycle; verify continuous PV ratings for heat management; consult material data sheets. |
| Thermal Expansion Management | CTE: ~100–200 × 10⁻⁶/°C (several times higher than metals). | Design housings for CTE mismatch; use press-fit for stable conditions, interference-fit for high load, adhesive bonding for thermal cycling or shock loads. |
| Shaft Surface Finish and Hardness | Ra: 8–16 µin (0.2–0.4 µm). Hardness: ≥55–60 HRC. | Maintain Ra within range for transfer film adhesion; use hardened stainless steel, hard-chromed steel, or ceramic coatings. |
| Electrical Isolation | PTFE is inherently dielectric and is used to prevent ground loops in motors. | Maintain insulation integrity in housings; use insulating sleeves, washers, or barriers under load and vibration. |
Applications Where Polymer Bearings Improve Efficiency
PTFE bearings in planetary gearsets and cooling pumps cut frictional losses, reduce parasitic drag, and extend service life—boosting drivetrain efficiency without complex lubrication systems.
Dry-running PTFE bushings in flap, trim, and thrust control actuators for aerospace applications significantly reduce weight, eliminate lubrication hardware, and deliver consistent torque across extreme temperatures.
In compact gearboxes for robotics and automation, PTFE bearings lower inertia and friction, enabling smaller motors, faster cycle times, and improved positional accuracy in high-speed automation.
In wind turbine yaw and pitch systems, PTFE bearings provide low-friction rotation, corrosion resistance, and electrical isolation to protect control electronics and improve responsiveness.
Conclusion
Polymer bearings, especially those manufactured from PTFE, can help improve the efficiency of electrified systems. Their extremely low friction, self-lubrication, and wide temperature range are direct benefits. And the performance of PTFE bearings can be customized through the use of fillers and hybrids.
If you’re considering PTFE as an option for plane bearings in an electrified system, contact Advanced EMC. Our engineers are ready to work with you to find the correct bearing solution for your design.
