OCTOBER 2024

W E L D I N G PRO DU CTIVITY

Ripple
effect
Consumables
TIG Welding
Robotic Welding

TRADE SHOW

Showcase

Fabtech 2024 Preview

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EDITORIAL SALES
Abbe Miller Alan Berg
Vice President/Publisher/Editor-in-Chief President
p: 847.749.6956 p: 732.995.6072
e: amiller@[Link] e: aberg@[Link]

Susan Woods Rick Edman

Managing Editor Director of Business Development
p: 847.602.1823 office: 203.656.1000
e: swoods@[Link] direct: 405.766.6290
cell: 917.751.4305
Jimmy Myers e: rickedman@[Link]
Senior Editor
p: 503.964.7519 Anita Edman
e: jmyers@[Link] Business Development Manager
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direct: 405.766.7262
ADMINISTRATIVE e: anitaedman@[Link]
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Office Manager/Accounting WELDING PRODUCTIVITY
e: msalazar@[Link]
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Warrington, PA 18976

EDITORIAL ADVISORY BOARD

Larry Cherne, market manager, laser
gases, Linde Gas & Equipment Inc.
Chris Vihnanek, senior director of metal
fabrication, Linde Gas & Equipment Inc.

PRODUCTION
Flip180
p: 818.855.7603
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EDITOR’S LETTER

SHELTER FROM THE STORM

As Floridians braced for Hurricane Helene’s For Fabtech exhibitors that rode out the
landfall two weeks ago, I watched from storm in Orlando – and for the attendees
afar along with the rest of the nation. I heading there – it is a relief to hear that
texted friends in southern Florida, asking the city seemingly sidestepped disaster.
if they had evacuated yet, and I worried Its inland location typically protects it
about industry friends that were most from major hurricane damage, but in
likely already in Orlando setting up for 2022, Hurricane Ian still managed to
Fabtech. I hadn’t reached out to my friends ravage Orange County with an estimated
in Georgia, though. It hadn’t really crossed commercial damage of more than $150
my mind. million. Thankfully, the measures that
are being put in place to protect the
But, as CNN put it in a recent article, state’s infrastructure, residents and
Hurricane Helene “laid waste” to vast resources are working.
swaths of the southeastern United States.
“Its sheer wind force and deadly floods left Ironically, much of what will be on
behind a path of destruction stretching display at the Orange County Convention
over 500 miles from Florida to the Southern Center was developed to protect
Appalachians.” With a death toll of more fabricators from the variety of challenges
than 230, more missing or unaccounted they face every day. From cutting-edge
for, and entire towns obliterated, the software and automation to powerful
impact of the hurricane was much greater equipment and thoughtful services, the
than most expected. exhibitors at Fabtech aim to set potential
customers’ minds at ease. So no matter
So, when a new, even bigger hurricane what literal or metaphorical storms the
began its march toward Florida, concerns industry might face in the future, it’s
of a repeat were swirling throughout the reassuring to know that there are tools
state. Fortunately, the areas hardest hit available to help.
from Helene weren’t in Hurricane Milton’s
path, and despite crossing the entire
peninsula, Floridians for the most part Abbe Miller
were spared from the worst-case scenario. Editor-in-Chief
With clearer skies ahead, the state can amiller@[Link]
now refocus on its recovery efforts.
 CONSERVING
CONSUMABLES

21
Departments
Features Editor’s Letter
[Link].

Special Report
News & People

13 Ripple effect New Products

Four AWS members embody the idea of membership by
making an impact on others

21
Consumables
Conserving consumables
Putting quality MIG welding consumables front and center 46
for a better bottom line
Sizeable sawing
When extra engineering is required for
TIG Welding a 10-ton automatic bandsaw, a sawing

26 Orbital origins
WELD IN G equipment manufacturer steps up to
PROD UCTIVITY the plate
For a variety of industries, the need for advanced
orbital TIG welding continues to grow

51

31
Robotic Welding
The best position Implementing automation
Boosting safety and efficiency with robotic welding New robotic material handling
workcells and positioners and cut list automation for sawing
operations gives customers the
efficiency they need

39
Laser Welding
Laser launch

31
A new laser welding cell – designed and built in America – TRADE SHOW

Showcase
makes its market debut

Fabtech 2024 Preview THE BEST

POSITION
[Link].

by Harry Moser, founder and president, Reshoring Initiative

Annual report offers

positive outlook
The Reshoring Initiative released its resilience, and fortify national and
annual report revealing strength and economic security.
longevity in the reshoring and foreign
direct investment (FDI) trends. The Geopolitical risk and climate change
strong movement is motivated by the have aligned corporate strategy and
risks associated with global politics U.S. industrial policy, leading to a
and climate change and by supportive notable increase in U.S. manufacturing
U.S. industrial policies. Reshoring plus investments. The cumulative number of Figure 1. Reshoring plus FDI manufacturing job announcements in 2023 added 287,000
FDI manufacturing job announcements jobs brought back since 2010 is nearing jobs, the second-highest year on record.
in 2023 continued to climb, adding 2 million (see Figure 2), which is about 40
287,000 jobs, the second-highest year percent of what was lost to offshoring. As government subsidies run competitiveness across various
on record (see Figure 1). out, new reshoring and FDI goods would minimize the need for
Essential industries supported by U.S. announcements are slowing. Future subsidies.
Bringing it home industrial policies like the Inflation progress will depend on new policies
Global events of the past several years Reduction Act, the CHIPS and Science that make U.S. manufacturing cost Most of the top factors for reshoring
– the pandemic, geopolitical risks and Act, and other government subsidies competitive rather than subsidize relate directly to supply chain
new industrial policies – have triggered have shown substantial growth. specific industries. A comprehensive optimization, which is focused on
a reindustrialization of America. U.S. Uppermost products include electric U.S. industrial policy is the best reducing costly risks from geopolitical
policies and geopolitical developments vehicle batteries, semiconductor chips mechanism to make domestic and climate change events. Incidents
will continue to shape the outlook and solar energy. These industries manufacturing sustainable in the long such as the Covid-19 shutdowns, war
for investments that shorten supply drove about 39 percent of the run. Measures such as substantial in Ukraine, Israeli/Hamas conflict,
chains, enhance domestic supply chain announced jobs in 2023. workforce investment and improved increasing tension over Taiwan

OCTOBER 2024 5
[Link].

and possibility of decoupling with the United States to stop importing

China highlight the urgent need for goods from a particular country due to
companies to consider reshoring and a negative geopolitical event.
nearshoring as safeguards against
catastrophic disruptions. The success or failure of recruiting
and training millions of workers will
Calculating risk determine the outcome of the current
Companies can utilize the Reshoring reindustrialization momentum in
Initiative’s free tools to compare either direction. Skilled workforce
alternative and local availability is the No. 1 criterion for site
sourcing options. The Total Cost of selection and, especially, for reshoring
Ownership (TCO) Estimator quantifies site selection. Clearly, the U.S. skilled
all relevant costs and risks. The workforce lacks the quantity and
Geopolitical Risk measure helps a quality needed for faster reshoring and
company decide whether any higher is at a disadvantage relative to many
U.S. TCO is worth paying to assure other countries. Nevertheless, about
component availability. Geopolitical 49 percent of cases mention skilled
risk is defined as the likelihood workforce availability as a reason they
that, within one year, a significant reshored, essentially tied for No. 2 with Figure 2. The cumulative number of jobs brought back since 2010 is nearing two million.
disruption in trade will occur, causing proximity to customers.

The annual number of citings of The Reshoring Initiative advocates to

workforce being a reason for reshoring make even more work reshorable by
has risen four times since 2013, policies like massive increases in skilled
but so has the overall number of workforce recruitment and training and
cases. In some industries, such as a lower U.S. dollar. Are you thinking
Global events of the past apparel, the lack of workforce makes about reshoring? For help, contact

several years have triggered a reshoring extremely difficult. This me at 847-867-1144 or [Link]@
factor is expected to become even [Link].
reindustrialization of America. more important as companies work to
fulfill their massive commitments to RESHORING INITIATIVE
domestic production.

OCTOBER 2024 6
 ESAB celebrates
120th anniversary
2024 marks ESAB’s 120th anniversary. Since its
inception in 1904 in Sweden, ESAB has become a
global leader in fabrication and gas control technology
with its groundbreaking products, workflow solutions and unique business
management system, ESAB Business Excellence (EBX). “This incredible milestone
would not be possible without the dedication of our associates around the world
and our relentless focus on driving innovation and continuous improvement, which
have been the cornerstones of our growth for more than a century,” said Shyam P.
Kambeyanda, president and CEO, ESAB Corp.

Yaskawa completes

PEOPLE
headquarters
expansion
Yaskawa Motoman announced completion of
its headquarters expansion in Miamisburg,
Ohio. The 185,000-sq.-ft. addition nearly
doubles the size of the company’s production space, optimizing its operational
capacity to meet the growing demand of the automation industry. The additional
manufacturing space will be utilized to engineer, develop, integrate and build
robotic systems, as well as providing additional space for the retrofit and rebuild of
previously deployed robots and systems. The expansion represents the first phase
of Yaskawa’s planned $200 million investment in the United States to support
its growth initiatives and its commitment to driving additional development and
production in the Americas.

BREAKING:
NEWS & PEOPLE

AWS and ASNT Fanuc America

Certification Services establishes
to collaborate scholarship fund
The American Welding Society (AWS) and ASNT Certification Services LLC Fanuc America Corp. established the Fanuc
announced a cooperative relationship aimed at advancing welding and Automation Endowed Scholarship Fund
nondestructive testing. The partnership allows for sharing of authorized training in collaboration with the SME Education
programs, examinations and certification facilities, creating a more cohesive Foundation. “Early on, we recognized the demand for advanced skills and it led us
and integrated approach to certification. Richard Arn, vice president of welding to establish our certified education program,” said Mike Cicco, president and CEO of
technology at AWS, stated, “The American Welding Society is excited to partner Fanuc America. “Now, through our new $1 million scholarship initiative, we continue
with the American Society for Nondestructive Testing to develop certification to champion education and help empower the next generation to learn, innovate
products that will benefit the members of both associations. We look forward to and fuel the growth of manufacturing in North America.” The endowment will
collaborating with them closely over the course of the next few months to begin to provide annual scholarships totaling at least $50,000 to students pursuing careers
materialize these opportunities.” in advanced manufacturing and automation across the United States and Canada.

Lincoln Electric named Welding student wins

to America’s Greatest at world competition
list by Newsweek
SkillsUSA competitor Wyatt Hansen, age 20, of Utah
Lincoln Electric Holdings Inc. was recognized as one of won a bronze medal in Welding at the WorldSkills
America’s Greatest Workplaces for Parents & Families 2024 by Newsweek. The award Competition, held Sept. 10-15 at Eurexpo in Lyon,
recognizes 1,000 U.S. workplaces based on reviews from more than 113,000 U.S. France. “Feels pretty good!” Hansen said of winning
parents across eight categories relevant to parents in the workplace. Lincoln Electric at the international competition. “We had a rough
was among 10 companies recognized in the Industrial Machinery sector. “We start, so we’ll take the bronze considering the week.” Hansen is a welding
appreciate the recognition of parents and Newsweek for our commitment in creating student at Utah State University Eastern who represented Utah at the SkillsUSA
a safe, engaging and rewarding workplace where employees can serve customers Championships in 2022 and 2023, earning a national gold medal in Welding in
and stakeholders while balancing their personal needs,” said Susan Edwards, senior 2023. “It’s been a privilege to be a part of the team and an honor to represent the
vice president, chief human resources officer, Lincoln Electric. United States in Lyon, France,” he said.

OCTOBER 2024 8
NEWS & PEOPLE To Submit Press Releases, Send Them to Abbe Miller at amiller@[Link]

LZH develops multi-laser Northern Tool +

beam welding process Equipment partners with
Laser Zentrum Hannover (LZH) is researching Monster Jam
ways to make welding thick plates in
Northern Tool + Equipment and Monster Jam are teaming up for a three-year
shipbuilding more reliable. Scientists are
partnership that will include retail, business-to-business and online integration. The
developing a multi-laser beam welding process
partnership includes becoming the official hardware retailer of tools and related
with customized beam shaping and a “Digital
equipment partner for Monster Jam and the announcement of the Monster Jam
Twin”-based integrated quality assurance
Garage outfitted by Northern Tool + Equipment. The garage will offer a hands-on
system. Researchers aim to facilitate welding of thick-walled components in the
experience that will inspire high school students to pursue careers in skilled trades.
15 mm to 30 mm range. They will combine various sensors to capture features
Frank Crowson, senior vice president and chief marketing officer of Northern Tool
related to the characterization of welds, such as weld reinforcement, seam
+ Equipment, said the partnership will provide students with a unique and special
width and distortion. Based on this data, they will develop an adaptive welding
experience to develop their skills with this one-of-a-kind build.
process control and an integrated quality assurance system that can classify
weld quality as acceptable or not acceptable.

Holston Gases announces

OSHA launches injury transition to third
report dashboard generation
OSHA unveiled an online tool giving users the Holston Gases will transition to a third-generation,
ability to search its severe injury report database family-owned business. Joe Baxter (right) will be named
and view trends related to workplace injuries occurring in states covered by president, succeeding Robert Anders (left) who has been president since 1997.
federal OSHA. The Severe Injury Report dashboard allows users to search and Anders will continue as CEO, approving all major decisions on the direction of
download data by year, industry, state, establishment name, and Occupational the company. Bill Baxter (middle) will continue as chairman of the board. Joe
Injury and Illness Classification System codes. The dashboard includes has been with the company for 15 years, starting in sales in Kentucky in 2009,
information on all severe injuries reported by employers covered under federal then moving to manager of the Lexington branch, then serving as regional vice
OSHA since 2015. OSHA encourages workers and employers to use the dashboard president of Kentucky. Upon his return to Knoxville in 2022, Joe assumed the role
to learn how severe injuries happen in their industries and use the agency’s of executive vice president of the company, directing the sales of multiple regions
available resources to help prevent workplace injuries. and becoming involved in operations.

OCTOBER 2024 9
 Miller releases cobot
welding solution
Miller Electric Mfg. LLC added touch
sensing and through-the-arc seam tracking
features to the Copilot collaborative
robotic welding system, making welding
automation easier and more effective. Along with a headless power source
design and teach pendant carriage, the cobot provides a convenient user
interface that eliminates extra steps like continuously going to and from the
power supply and teach pendant. Instead, the user’s attention is focused on the
welding torch and cobot arm, making the cobot intuitive and natural to welders
of all skill levels. Copilot also features the new Auto Deltaweld as its welding
power source, which means its input power flexibility accommodates single-
and three-phase input.

Walter releases

PRODUCTS
new welding helmet
Walter Surface Technologies launched its
new Spy auto-darkening welding helmet from
ArcOne. Thanks to its large viewing area and
TrueColor technology, welders will be able
see more of their work clearly, setting the
foundation for quality welding and productivity gains. To keep welders at ease
in their work, the helmet’s ratchet headgear is reinforced to minimize pressure
points and an integrated foam pad ensures a cushioned fit during extended use.
With this added support, welders can stay focused for longer periods, making a
full day’s work less tiring and more productive.

OCTOBER 2024 10
NEW PRODUCTS

Lincoln Electric updates InduSuite launches

twin-wire welding solution cloud-based gas
Lincoln Electric announced the latest evolution of the monitoring software
HyperFill twin-wire welding solution with the addition of
InduSuite, ESAB’s platform of software
HyperFill STT (surface tension transfer) for increased travel
applications for welding, cutting and
speeds in pipe welding applications. HyperFill technology,
robotics, introduced FloCloud, a gas
combined with the waveform benefits of STT, allow pipe
monitoring software solution. It enables users to track gas process parameters,
manufacturers to take advantage of faster, more precise
analyze gas consumption, and identify gas leaks and over-consumption. FloCloud
welding. The STT waveform is primarily used on open root
combines GCE’s brand of gas control products with InduSuite’s WeldCloud software
pipe welding, making it possible to increase root pass travel speeds up to 57
application platform to build a gas manifold with Mesh WiFi-enabled pressure and
percent and delivering increased pipe diameter (inches per day). The combination
flow sensors that communicate data to the FloCloud online application. FloCloud
of this waveform with the productivity gains of HyperFill allow operators to see
features an easy-to-use analytics dashboard and reporting system that tracks every
increased efficiencies throughout the welding process.
end user point and sends notifications if gas pressure drops or if gas flow is outside
of WPS parameters.

Newly engineered
abrasive belts from ABB improves
Norton cobot accuracy
Norton | Saint-Gobain Abrasives introduced ABB Robotics launched Ultra Accuracy,
next-generation NORaX N889 micro- a new feature for its GoFa cobot family.
structured abrasive belts for producing Applications include laser welding of
consistent, fine finishes across a range car parts and laser cutting in metals
of industries. The belts feature an engineered, high-performance micron-grade fabrication processes. It can also be
aluminum oxide grain structured in a fine 3-D pyramid pattern, which is well-suited used for accurate positioning of additive
for lower pressure applications where belt flexibility is needed. The engineered layers in building prototypes in 3-D printing. Additional benefits include the
abrasive slowly erodes during grinding, exposing new, sharp abrasive grains combination of precision with speed and a full range of motion. GoFa cobots
resulting in long belt life, higher quality finishes, faster cutting rates and an ability offer full 6-D motion across their entire workspace upon delivery, without
to reduce finishing steps. A flexible J-weight backing conforms to complex contours requiring additional calibration work, providing the flexibility and mobility to
for superior, high-quality finishes. handle a broader range of tasks.

OCTOBER 2024 11
NEW PRODUCTS To Submit Press Releases, Send Them to Abbe Miller at amiller@[Link]

optrel releases PAPRs Kawasaki

in North America Robotics introduces
education robot
optrel Inc. introduced Helix Pure Air powered
air purifying respirators (PAPRs) and Clearmaxx Kawasaki Robotics offers Astorino, an
PAPRs to the North American market. The PAPRs affordable educational robotics platform for
use an advanced motor blower to allow air to industrial and technical education providers.
pass through a filter, removing contaminants and It offers the capabilities of a modern industrial robot at a fraction of the cost
supplying purified air to the user’s headgear. The lenses include Shadetronic of other robots for the educational market, enabling educators to more easily
and Fadetronic auto-darkening filter technology to provide optical clarity for equip students with the foundational, real-world skills needed as manufacturing
welding and a wide field of view for grinding and other industrial applications. continues to evolve. The platform also supplies STL files so students can rapidly
The airflow system features automatic and manual airflow adjustments, ensuring print 3-D replacement parts for 99 percent of the robot. At the core of Astorino
a comfortable breathing experience even during extended use. The products are is a 1-kg payload, 6-axis robot with a structure and programming environment
available through MSA Safety’s authorized distributor network. nearly identical to that of a Kawasaki industrial robot.

New saw and clamp YesWelder unveils

solution from Esco Tool new welder
Esco Tool released a pneumatic saw and clamp YesWelder launched the Firstess DP200
setup that produces a stress-free cut on thick steel welder. This advanced welding machine has a
plate without a heat-affected zone. The APS-438 air- user-friendly design and features an intuitive
powered saw and quick-clamp sets up fast using a color display that simplifies the entire welding
2-in.-wide steel track and two wedge-style clamps that process. The built-in intelligent parameter
attach to steel plate up to 15 in. wide and 3.5 in. thick. recommendation system allows users to get
Suited for on-site fabrication of ships and other large started instantly, providing a seamless entry into welding. With step-by-step
structures, the clamp lines up quickly and eliminates guides and real-time feedback, even those new to welding will achieve good
the damage and danger associated with torch cutting. Powered by a 3-hp results quickly. The welder offers a high degree of customization, enabling
pneumatic motor, the saw mounts rigidly onto a bracket that glides along a steel professionals to fine-tune settings to meet stringent welding requirements. This
track on four V-grooved steel wheels. level of control ensures professional-grade capabilities.

OCTOBER 2024 12
by Abbe Miller, editor-in-chief

RIPPLE
EFFECT
Four AWS members embody the
idea of membership by making an
impact on others

OCTOBER 2024
 T
he Fabtech 2024 and mentorship has been building
theme for the and snowballing for years. Today,
American Welding the impact of member relationships
Society (AWS) is strong and helping to improve the
is innovation, greater community.
inspiration and
impact. The show, which is being PAY IT FORWARD
hosted in Orlando, Fla., this year will Tom Kostreba could be spending his
feature cutting-edge technologies days on a fishing boat or a golf course,
in forming, fabricating, welding and but instead, he’s cultivating the next
finishing. With more than 1,500 generation of welders. Almost as soon
exhibitors, innovation will be in the air. as he retired from his long-time career
“I started teaching because I
at Wabtec Corp. as a locomotive test
In terms of the inspiration and impact technician, he picked up a few new love working with people and
reflected in AWS’s Fabtech theme, hats to wear. He’s the director of wanted to get more involved with
that, too, will be in the air. It will be his local AWS district, the national
embodied in the thousands of AWS fabrication chairman for SkillsUSA, an students. Now, I’ve got a front-row
members that will be in attendance; AWS certified welding inspector and, seat to our future.”
because, as any AWS member knows, perhaps most important, he’s also a
being a part of the organization is like welding instructor at Erie High School Tom Kostreba, welding instructor, Erie High School
being a part of a family. At AWS events in Erie, Pa.
like Fabtech across the country and
throughout the year, new connections “I started teaching because I love
are made that will last a lifetime. working with people and wanted to
get more involved with students,” he
To understand the ripple effect that says. “Now, I’ve got a front-row seat to
AWS membership can have, one our future.”
doesn’t have to look far. Take the folks
of AWS District 10 as a good example. In the spirit of paying it forward,
In northwestern Pennsylvania, the Kostreba says his passion for teaching
story of one person’s encouragement and mentoring started early in his

OCTOBER 2024
life when one of his own welding As an active AWS member, he gets
instructors took him under his wing. even more opportunities to share
Over the years, working with others his passion for mentorship and for
and encouraging them to be the best the industry. According to just about
versions of themselves unofficially anyone who’s met Kostreba, his
became his life’s work. passion is contagious.

“One of my favorite things

about being active in AWS is the
networking,” he says. “Whether it’s
at the AWS Leadership Symposium,
the Instructors Institute, or in a
section meeting or CWI roundtable, I
don’t forget the people I meet.”

And they don’t forget about

him. In fact, many might not be
where they are today without
Kostreba’s encouragement.

FRIENDLY NUDGE
Donna Newell is one of those
people. Newell is an AWS certified
welding inspector and certified
welding educator and is also the
lead welding instructor at Erie High
School. Early in her career, she
Tom Kostreba is the director of his local AWS
took a welding class that was led by
district, the national fabrication chairman for
SkillsUSA and a welding instructor at Erie Kostreba; because, of course, he’d
High School in Erie, Pa. He is also an AWS been moonlighting as a welding
certified welding inspector. instructor while also working his
full-time job. When he slept, no one some point, he told me that I would benefit from a little nudge from time where I got a degree in mechanical
really knows. be a good teacher. Even though I to time. engineering technology.”
thought he was crazy, I went for it
“I’m where I am today because of and fell in love with it. Later, I started LEAP OF FAITH Initially, he signed up for an associate’s
Tom,” she says. “He helped me get working at a post-secondary institution When Cody Nikolai graduated from degree, but by the time he was halfway
my first couple of welding jobs and at and rewrote the curriculum for their Erie High School, his time in Newell’s through his second year, he signed
welding program, condensing it from welding program helped land him a on to pursue the four-year degree.
15 months to 12 months. job with a local fabricator. But Newell Throughout those four years, he
wasn’t necessarily satisfied with that; maintained a 4.0 GPA and earned
“From there, a position opened up in a she knew he was destined for more. about $20,000 in AWS scholarships,
brand-new program here at Erie High “mostly because of his good grades,”
School, which meant that I could set “He just wanted to graduate and make Newell says.
it up how I wanted from the ground money,” Newel explains. “He had a job
up,” she adds. “I was nervous, but with that paid well, but I told him, ‘you’re Since graduating, Nikolai has been
Tom’s encouragement, I ended up too smart for that. You need to be working as an engineer at The Warren
doing it. That was 10 years ago.” an engineer.’” Co., a steel service center in Erie, Pa.
When asked if he has plans to do any
Newell has been involved with AWS for With enough prodding and pleading type of mentoring or teaching, he
as long as she’s known Kostreba. “He – and with the prospect of receiving a says he would drop everything to help
got me involved right away,” she says. scholarship from AWS (Newell makes Newell if she asked him.
As an AWS member, she’s served in sure that all of her students become
nearly every board position available AWS members during her program) “I’m all about helping out the younger
and is currently treasurer of her local – Nikolai started warming up to the people because I was one of those
AWS section. idea. Because he trusted and looked younger people not that long ago,” he
up to her, he took a leap of faith to try says. “If I can be an extra hand to help
Unsurprisingly, Newell caught the something outside of his comfort zone. Donna and Tom put it into a kid’s mind
bug for mentorship from Kostreba that, ‘hey, there are so many different
Donna Newell is the lead welding instructor
and ever since, she’s been lifting up “I’m not a big fan of school, so I was paths you can go down just by going
at Erie High School and treasurer of her
local AWS section. She is also an AWS her students to help them reach the happy to just start working right to a technical college,’ I’m happy to.
certified welding inspector and certified potential she sees in them. To say the after high school,” Nikolai says. “But Hopefully, it can help someone have a
welding educator. least, most high school students can Donna convinced me to go Penn State brighter future.”

OCTOBER 2024 16
PASSING THE BATON fabrication shop where Nikolai
The NEW TOOL
Riley Warren is an AWS certified
welding inspector and the fifth-
is employed. Warren, more than
anyone perhaps, understands
for Your Welding Toolbox
generation owner of The Warren the important duty of passing the
Co., the steel service center and baton. He works with local trade

LightWELD
schools and community colleges ®

to push the development of their

programs and get their students
America’s #1 Handheld Laser Welder & Cleaner
into the workplace.

“Our company is dedicated to

supporting the next generation of
welders,” he says. “It’s a passion of
mine and a passion of our business.
We want to reach out and support
the next generation and get them
the hands-on experience that young
people in the technical trades really
need and thrive on.”

In addition to giving recent grads

like Nikolai a chance, Warren
dedicated a space in his shop for
Kostreba and Newell’s students to
get practical experience welding,
inspecting, and repairing and
building parts. Warren also donates
Cody Nikolai graduated from Erie High 100 Optimized Welding Presets Minimal Heat & Distortion Fast, Safe & Easy to Learn
material to the high school program
School and, with the encouragement of
and steps in with any equipment
his welding instructors, went on to earn
a degree in mechanical engineering needs Kostreba and Newell
technology from Penn State University. might have.
LEARN MORE
OCTOBER 2024
[Link]
 LightWELD
®
“He’s bringing kids in and opening they’re in the shop. It gives them a
up their eyes to what shop life is really taste for what working hard feels like
like,” Kostreba says. “When they’re and helps them connect all of the dots Handheld Laser Welding & Cleaning

there, we expect them to work like for what we’ve been teaching them.”

BUILDING
THE FUTURE
LEARN MORE
[Link]

Riley Warren is an AWS certified welding inspector and the fifth-generation owner of The

ONE WELD AT A TIME

Warren Co., a steel service center and fabrication shop in Erie, Pa.
STRONG BONDS he is helping me out of a really big jam
Clearly, the bonds that have been made because we have a big show coming
in this little corner of Pennsylvania are up to hopefully gain more donors and
strong. And that ripple effect is bound sponsors. Knowing that, he said he
to carry on – especially for the students would cut parts for us. So again, it’s just
that will pass through Kostreba’s and that wonderful partnership that we
Newell’s classroom in the years to come. have. I don’t know what we would do
without his support.”
While Newell won’t be heading to
Orlando for Fabtech this year, she will
be bringing her students to Chicago for
Fabtech 2025.

“My students always go to Fabtech when “I’m all about helping out the
it’s in Chicago, and we pay our own way,” younger people because I
she says. “Everything that we build in
the shop over the course of two years was one of those younger
is used to pay for transportation, hotels people not that long ago.”
and food. We spend four days at the
show, and if we have the budget and Cody Nikolai, engineer, The Warren Co.
time for it, we squeeze in some touristy
stuff, too. It’s a lot of fun and a great
experience for the students.”

Unsurprisingly, Warren is always happy

to help the students throughout the AMERICAN WELDING SOCIETY
year as they raise money for the trip.
ERIE HIGH SCHOOL
“Riley knows how important donations
are to us,” Newell says. “In fact, my
THE WARREN CO.
plasma cutter is currently broken, and
Techgen Media Group’s Alan Berg
President
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OCTOBER 2024
by Andy Monk, product manager, consumables, Bernard

CONSERVING
CONSUMABLES
Putting quality MIG welding
consumables front and center
for a better bottom line
 T
ime is money, and cooled MIG guns as the shop’s main
if you’re wasting offenders. From a maintenance
time, you’re wasting perspective, hoses were constantly
money. This adage leaking, wires inside the guns were
rang all too true breaking, contact tips were burning
for one Midwest out at a shockingly fast pace and
manufacturer of equipment used liners were failing prematurely. In fact,
for managing difficult-to-process
liner issues were so frequent that it
materials across the mining, resource
translated to five to seven hours per
recovery, bulk processing and
week in lost time.
foundry industries. Creating high-
caliber equipment for these niche
The manufacturer realized it
industries doesn’t allow for slowdowns
needed to assess its equipment and
– especially across the manufacturer’s
welding operation.
determine whether a better solution Switching to a new type of gun and
existed to mitigate the constant
a higher quality consumables system
Over the past several years, however, repairs and excessive consumables
this manufacturer noticed an uptick consumption. The shop’s maintenance resulted in a significant improvement to
in MIG welding gun maintenance and tech reached out to its welding
the manufacturer’s bottom line.
consumables consumption. Because distributor, who recommended
it was leading to unwanted downtime, Bernard BTB air-cooled MIG guns with
the company decided to run the AccuLock S consumables. Unfamiliar
numbers; the result was shocking. with those products but praised by
Most notable was the repeated gun the distributor, the manufacturer was
breakdowns and excessive contact tip eager to learn more.
consumption, all of which substantially
slowed down production. The costs of MEET THE FAMILY
repairs, consumables and lost labor was Welders need tools they can rely on,
estimated at around $45,000 a year. which is exactly what led Bernard to
create the AccuLock consumables
Looking into the issue further, the system. The system’s components
manufacturer pinpointed its water- have been engineered to extend the
life of consumables and improve and the shielding gas cools the tip tail,
performance in semi-automatic MIG facilitating longer life and reducing
guns – ultimately giving welders a replacement frequency. Additionally,
premier option to use on the job. mating tapers on tip-to-diffuser and

Pipe & Beam

diffuser-to-neck connections provide
AccuLock S consumables for semi- good electrical conductivity.

Cutting Machines
automatic MIG guns are compatible
with conventional rear-loading liners The consumables also provide less
and AccuLock S dual-locked liners. rework and ease of maintenance. The
When paired with conventional liners, steel retaining ring on the diffuser Automating craftmanship to give the world of
AccuLock S consumables provide helps keep the threaded nozzle steel the freedom to create
longer tip life. The contact tips are 60 in place during use, and cleaning
percent buried within the diffuser for and coarse-thread contact tips
less exposure to the heat of the weld, speed replacement.

Since our founding back in With more than 1,000 machines

1984, HGG has been dedicated installed globally, we are a
to giving the world of steel the trusted partner to the world’s top
freedom to create. We provide companies in steel construction,
you with a competitive advantage shipbuilding, offshore, and pipe
in your market, transforming processing.
your fabrication process into a
seamless operation. Our strength lies in the unique
synergy between our two business
divisions: HGG Profiling Equipment
and HGG Cutting Services. We
build the world’s best 3D profiling
machines in-house and use them
daily for their intended purposes.

See it at More information:

Booth: S24177 [Link]
Bernard BTB MIG guns with AccuLock S consumables are versatile enough to work across an
array of jobs.
HGG Profiling Equipment Inc. | 7950 Breen Drive - Houston, Texas
Conventional rear-loading liners don’t and concentrically aligned to the tip time by eliminating quality issues processing the team’s feedback and
account for changes in length as the and power pin to ensure smooth, stemming from liners that are trimmed making adjustments allowed the
power cable grows and shrinks with uninterrupted delivery of wire to the too short. Also, the system accelerates manufacturer to arrive at a decision.
the twisting that occurs during the weld puddle. welder throughput. Fewer points Converting to the BTB air-cooled MIG
welding process. This can result in of failure can help reduce welder guns and AccuLock S consumables
the liner being improperly positioned When paired with AccuLock S training; shorten troubleshooting lists; with the dual-locked liner was the
behind the contact tip, causing drag, consumables, the dual-locked liner eliminate liner misalignment and gaps; right solution.
wire chatter and feeding issues. system offers additional benefits. The and minimize downtime caused by
Upgrading to the AccuLock S dual- liner replacement process is error- burnback, birdnests and erratic arcs. Prior to using the Bernard guns and
locked liner system combats those proof. AccuLock S liners are cut flush consumables, the shop contended
issues – and provides innovative with the back of the power pin to EQUIPMENT UPGRADES with multiple MIG guns being out
features where the liner is locked ensure accurate replacement every After learning about the power of of commission and needing repairs
pairing the consumables system every month. After implementing the
with an air-cooled MIG gun, the new equipment, maintenance needs
manufacturer decided to test the reduced significantly. Additionally,
products among its welding operators. the durability and performance of
It was important that the guns and the gun and consumables system
consumables be versatile enough improved productivity tremendously.
to work across an array of jobs and
adhere to the output quality for which The contact tips run significantly
the company was known. On any cooler and last two to three times
given day, operators could be welding longer than the ones used previously,
anything from A-36 steel to AR-500 making for less tip consumption and
plate in thicknesses up to 8 in. and on a downtime. In total, the manufacturer
variety of weld joints. The manufacturer achieved approximately 10 percent
took a thorough approach to testing, more productivity from reduced
making sure performance met or downtime. Additionally, it realized an
exceeded expectations. ROI within 14 months and achieved
its goal of eliminating the $45,000
When paired with AccuLock S consumables, the AccuLock S dual-locked liner system is Eight months of using the new system cost in repairs, consumables and
error-proof. across a variety of applications, lost labor.

OCTOBER 2024 24
AccuLock S consumables have been engineered to extend the life of consumables and
improve performance in semi-automatic MIG guns.

Switching to a new type of MIG gun operators can spend less time being
and higher quality consumables frustrated and more time being
system resulted in a significant productive. When quality, consistency
improvement to the manufacturer’s and efficiency are key, investing in the Liners were failing prematurely. In
bottom line. The welding operators right products will help a shop reap the
fact, liner issues were so frequent
are impressed with how long the liners big rewards it’s after.
last and the fact that the guns and that it translated to five to seven
consumables run cooler, reducing hours per week in lost time.
spatter and cleanup. No longer having
to contend with leaking water-cooled BERNARD
guns or persistent liner issues, the
by Justin Brodehl, global sales director for AMI, ESAB

Orbital
origins
For a variety of industries, the
need for advanced orbital TIG
welding continues to grow
 W
hat do semi- but orbital TIG welding machines are
conductors extremely repeatable. Also, a manual
and pharma- welder can only lay down so many
ceuticals have welds a day. With a fleet of orbital TIG
in common units, fabricators can make thousands
with wine of welds per day. Further, the enclosed
and waffles? They all rely on high-puri- design of the welding head ensures
ty gases and liquids that flow through good shielding gas coverage to
stainless steel tubing fabricated with prevent contamination, a factor that
orbital TIG welding systems.
is important when impurities are
measured in millions of particles per
Orbital TIG welding is integral to the
cubic foot of air.
performance of the semiconductor
fabrication plants that turn raw silicon
A manual welder can only make so
DECADES OF ADVANCEMENTS
wafers into the integrated circuits that many welds a day. With a fleet of
In the late 1970s, Arc Machines Inc.
are at the heart of Silicon Valley as well
as for the biopharmaceutical industry (AMI), an ESAB brand, changed the orbital units, fabricators can make
and household names in food, dairy nature of automated TIG welding
thousands of welds per day.
and beverage manufacturing. when it launched one of the first
orbital TIG systems with a closed
The quality and reliability of the welding welding head. The system could weld
equipment makes a huge difference tubing with a wall thickness up to
in Silicon Valley, and fabricators don’t 0.180 in. and diameters ranging from
have a lot of extra spare time – the 0.125 to 7.5 in. Among its advantages:
faster end users can launch a new
product, the more revenue they can • Field and shop location flexibility
generate. These applications require by using 120 or 230 VAC primary
an automated process for consistency, power
productivity and quality.
• Conventional and pulsed TIG
The welding speed, heat input and gap outputs of 100 A (on 120 V) or 150 A
might vary with manual TIG welding, (on 230 V) at 100 percent duty cycle
 • Travel start delay, current slope arc rotates during the background
controls, gas pre-purge and gas current pulse.
post-flow control
MODERN DAY TECH
• Remote control pendant Today’s state-of-the-art orbital TIG
welding technology is reflected in the
• Automatic timer functions, including Model 217 power supply. It weighs
the ability to step through four 66 lbs. and features a high-resolution
different current levels/pulsing color touchscreen and advanced
outputs to reduce heat input as the control capabilities. The screen is
weld progresses IP65-rated against the dust and
moisture found in field conditions
• Extreme durability for shop and and offers excellent visibility in low-
field work light environments. It offers “canned
programs” with easy menus to scroll
Technology took a step forward in through to access information. The
1989 with an orbital TIG welding digital touchscreen makes it even
machine that weighed 79 lbs. and had easier for operators to enter the
a compact design (11 in. by 22.75 in. welding program and modify it when
by 18.75 in.), which made it quick and they need to troubleshoot welds.
easy to set up onsite. The machine had
welding output modes for TIG, pulsed With modern electronics, today’s
TIG, step and tack; a memory capacity orbital TIG power supplies can store
of 100 weld schedules; and the ability 1,000 weld schedules and feature five
to set 100 levels. A level is the ability welding modes: tack, pulsed, step, no-
to program changes in the current, pulsed, S3 and pulsed S3.
pulse times, rotation speed and modes
as the arc rotates around the tube. Pronounced “S cubed,” the last two
Arc Machines Inc.’s advanced range of automated orbital TIG welding equipment is used to A mode can be continuous rotation modes are named for the three S’s
fabricate tubing. or step rotation, which is where the that define the weld – “single slope,

OCTOBER 2024 28
 Weld with us
in Orlando
Enhance every weld no matter
who holds the torch. At FABTECH
you can test out our range of
welding equipment from portable
machines through industrial
systems and additive welding.

Precision welds and ease of use

are just some of our specialties.
See this for yourself at one of our
four welding stations.

Come by our booth to learn how

your welding can benefit from the
latest in arc technology.

Get a sneak peek at what you’ll see

in our FABTECH booth.

Check it out

The Model 217 power supply features a high-resolution color touchscreen and advanced Experience these products and
control capabilities. The screen is IP65-rated against the dust and moisture. more at our booth B27027,
Booth
[Link] Sept. 11-14, 2023.
W4364
single” pass – which is a linear FURTHER FEATURES
reduction of average amperage from Other convenient features in modern
the beginning to the end of the weld. orbital TIG welding systems include an
Compared to the industry standard arc start counter as some applications
of setting a four-level weld schedule require an electrode change after a
(one level for each 90 degrees of specified number of arc starts. There
rotation), S3 creates consistent bead are even weld data recording machines
width and fusion from the beginning that can sample real-time data during
to the end of the weld. It can help the weld sequence. These systems
avoid the bead becoming narrower can store weld data that includes
and then widening (the “Christmas time, amperage, arc voltage and RPM
tree effect”) when switching in memory under a programmable
between levels. weld identification name. The data As the semi-conductor and
can be exported to an Excel format
biopharmaceutical industries continue
These power supplies also feature for identification, documentation and
an auto-generated weld schedule traceability purposes. to grow in America, the need for
function. The operator enters four
advanced orbital TIG welding systems
parameters (welding head model, As the semi-conductor and
tube material, diameter and wall biopharmaceutical industries continue will also continue to grow.
thickness) and the machine populates to grow in America, the need for
the weld schedule with parameters advanced orbital TIG welding systems
from an on-board library based will also continue to grow – for years to
on best practices. The auto weld come. The quality and reliability of the
schedule function reduces the welding equipment affects that growth
chance for operators to enter an in a positive way.
incorrect value and greatly reduces
setup time, especially for a less
experienced operator. If the operator ARC MACHINES INC.
needs to fine-tune parameters,
the touchscreen enables fast and ESAB
easy edits.
 by Josh Leath, senior product manager,

Yaskawa America Inc., Motoman Robotics Division

The best
position
Boosting safety and
efficiency with robotic welding
workcells and positioners
 W
ith an ongoing that is impacting fabricators and
competitive production capabilities across various
manufacturing sectors. The American Welding Society
landscape, any (AWS) provides its estimated welding
manufacturer, labor deficit regularly with recent
large or small, updates that the United States is
is constantly seeking new ways to expected to experience a shortage of
boost their production processes, 330,000 welders by 2028 with 82,500
improve safety and increase average welding jobs to be filled
operational efficiency. Robotic welding annually from now until 2028.
technology has significantly advanced
since its early adoption, particularly This is equivalent to almost 50 Pre-engineered robotic welding
through the adoption of pre-engineered percent of the number of U.S. welding
robotic welding workcells. professionals. The welder shortage
workcells are designed with
is due to a combination of factors, integrated safety features to
One of the originators in this space primarily an aging workforce and
lack of skilled new welders entering
mitigate risks and liability.
from the early 1990s was Yaskawa
Motoman and its line of ArcWorld the workforce.
workcells. Standardized workcells like
this are popular for their professionally This shortage of welders, whether
engineered safety, reliability and skilled or new, has prompted many
efficiency. These cells have come a companies to at least explore
long way over 30 years with the latest automation as a viable solution to
iterations offering more modularity and mitigate the risks of the labor gap.
flexibility with matching positioners, Fabricating leaders are trying to find
further boosting the versatility and ways to duplicate the efficiency of
performance of robotic welding systems. their current staff. By adopting robotic
welding systems, manufacturers
Fabricated metals manufacturing is can overcome their labor woes
facing a significant workforce shortage while increasing overall profitability,
efficiency, safety and quality plus medium-size enterprises, as well, driven
better retention of their highly valued by the need for competitive pricing,
welding team. consistency and the ability to overcome

RISE OF WELDING AUTOMATION

labor shortages while achieving
reshoring goals. According to a report
WE CAN HELP YOU OR YOUR
The adoption of welding automation by the National Robotics Education CUSTOMERS REACH KEY OBJECTIVES
has always been steady with larger Foundation, approximately 40 percent
corporations. However, it has been of American manufacturing companies OBJECTIVES RESOURCE/ACTION EXPLANATION
on a steep incline recently in the have implemented or are planning to
Convince customers to import
United States amongst small and implement robotic welding systems in Increase sales
TCO Estimator less and source more from you.
[Link]/TCO-estimator We helped one company win a
$60 million order vs. China this way.

Import Substitution Program (ISP) Identify importers of what you

Find new customers produce. Use TCO to convince them
[Link]/ISP to buy from you instead.

TCO Estimator
Reduce cost and
[Link] 20% to 30% of imports would be
deal with supply
impact-of-using-tco-instead-of- more profitably sourced here.
chain disruptions
price/

Reshore Expect 50% inventory reduction.

Reduce inventory
Find local sources One SKU was cut 94%.

Employees will be more loyal if you

Skilled workforce Reshore
are loyal to your community.

See if reshoring makes economic sense for your company or for your
customers who have offshored. Email or call the non-profit Reshoring Initiative
at info@[Link] or 847-867-1144. For more details read ‘Moser on
Manufacturing’ in this issue.

Reshoring Initiative | 847-867-1144

Info@[Link] | [Link]

Yaskawa Motoman’s line of ArcWorld workcells are popular for their professionally engineered
safety, reliability and efficiency.

OCTOBER 2024
their operations (National Robotics in adopting a significant amount of Heavy equipment manufacturing: reducing manual labor with limited
Education Foundation, 2022). robotic welding due to the consistent Industries involved in the production of programming required and the ability
high volume of production and the heavy equipment, such as agricultural, to save robot jobs for future use.
The key industries that are leading need for precise, high-quality welds, construction and mining machinery,
the charge in adopting welding especially in safety-critical parts. benefit from robotic welding due to PRE-ENGINEERED CELL BENEFITS
automation include: Robotics streamline the welding of long arc-on times on high-deposition “Safety first” is more than an idiom
complex assemblies and ensure welds that demand structural integrity. in any manufacturing environment.
Automotive: The automotive sector traceable consistency across millions Such environments can be both dull Especially in welding operations,
has been the primary trendsetter of units. and dirty for workers, often making it factors like high temperatures,
difficult to retain welding talent. electrical shock risk, arc flash and
potentially hazardous fumes expose
Aerospace: Aerospace manufacturing workers to real health risks. Pre-
requires precision weld quality to engineered robotic welding workcells,
meet stringent weld specifications such as ArcWorld cells, are designed
and certification testing for crucial with integrated safety features to
reliability. Robotic welding systems are mitigate these risks and liability.
being used more and more to join a
variety of metal components of aircraft Standardized workcells come with
and spacecraft. These components built-in safety mechanisms including
have been an automation challenge protective enclosures, safety interlocks
in the past due to short production and advanced sensing technologies.
runs with high-tech alloys, but new and The cells are outfitted with arc screens
standardized welding technology has and barriers that protect nearby
made this more feasible. human operators from the ultraviolent
light and sparks generated during the
Fabrication and metalworking: For welding process. Also, the integration
general metal fabrication and custom of advanced sensors and cameras
or contract metalworking, robotic allows for real-time monitoring
welding provides the flexibility to and adjustment, ensuring that any
The servo-driven RM2 positioner provides exact coordinated motion with the robots to provide handle diverse and complex parts with deviations or anomalies are quickly
access to all weld joints. efficiency, improving throughput and addressed, thereby reducing the risk

OCTOBER 2024 34
of accidents and improving overall components and robust engineering to
workplace safety. ensure long-term performance.

Reliability in welding operations is The components in ArcWorld workcells

critical to maintaining consistent are subjected to rigorous testing and
product quality and minimizing quality control measures before they
unplanned downtime. Pre-engineered are deployed as a standard product.
systems are designed with reliability This comprehensive testing process
in mind, incorporating proven and working with component suppliers

The AR Series robots are designed for easy programming access into tight spaces and can be
fitted with a variety of torches, such as the water-cooled Binzel torch shown.

OCTOBER 2024
ensures that the systems are not welding process with optimized
only capable of performing complex robot movements and workflow
welding tasks with precision but are configurations that minimize idle
also durable enough to handle the times and maximize throughput. This
rigors of continuous operation. By leads to higher production rates and
investing in a pre-engineered system, better utilization of resources.
companies benefit from reduced
maintenance requirements and fewer Consistent quality: The repeatability
unexpected breakdowns, leading to of robotic welding ensures that each
more stable production schedules weld is consistent, reducing the
and lower operational costs. need for rework and quality control
interventions. This consistency
Increased efficiency is a primary renders higher quality products and Robotic welding technology has
driver of productivity in metals fewer defects.
manufacturing. The pre-engineered
significantly advanced through
nature inherent to standard systems ADD IN POSITIONERS the adoption of pre-engineered
like ArcWorld workcells immediately Yaskawa’s RM2 series of Ferris wheel-
robotic welding workcells.
contributes to operational efficiency style positioners represent an ongoing
in a few ways: improvement in part handling
designs, offering a modular swing
Reduced setup time: The workcells arm and component design that can
are pre-configured and tested, handle multiple payload capacities
which means they can be quickly to meet a wide range of cycle time
installed and integrated into existing and tooling size requirements.
production lines. This reduces the Here are four ways the positioner
time needed for setup and calibration, enhances the performance of robotic
allowing companies to ramp up welding systems:
production faster.
Enhanced workflow and ergonomics:
Optimized workflow: The workcells The Ferris wheel design minimizes
are designed to streamline the floor space and reduces pinch
potential from legacy “H-Frame” turning positioner axes. Full overhead allows for easy customization and The 1,275-kg capacity is well-suited
designs, which also improves the crane access and positioner lock pins scalability. With tooling spans for medium-size parts and tooling,
accessibility for the operator loading allow for swapping out tooling or large from 1.5 m to 5 m and diameters providing a balance between payload
parts during the welding process. An parts without disturbing the parts from 1.3 m to 1.9 m, this size and capacity and maneuverability.
operator can load and unload parts being processed. even payload modularity enables
on the operator side while the robot companies to adapt the positioner to The 2,850-kg capacity is for heavy-
welds parts with full coordinated Modular design: The positioner their specific requirements without duty applications. This configuration is
motion between robot and part- features a modular design that the need for extensive modifications. capable of handling large and robust
Whether dealing with small, intricate components. The high capacity ensures
parts or large, heavy components, that even the most demanding tasks
the positioner can be configured can be managed efficiently.
to handle various payloads and
tooling setups. Simple setup: Yaskawa had patented
the MotoMount tooling compliance
Flexible payload capacities: The RM2 device with the goal of taking beam
series is designed with appropriately stress off a positioner headstock,
sized servo motors and fully sealed tailstock and tooling, especially in
reducers to accommodate different circumstances where flooring or
payload capacities and minimize setup tasks did not ensure perfect
maintenance, offering flexibility alignment. That design has carried
that is essential for manufacturing forward to the main trunnion axis
applications. Each combination of the Ferris wheel positioner to
is tuned for maximum speed further take any beam stress off the
and reliability. positioner main axis and arc shield for
wider span positioners. This ensures
The 750-kg capacity is ideal for easy setup, quick tooling swaps and
lighter parts and tooling. This long reliable use of the reducers used
configuration is suitable for tasks in the gearing system.
that require precision and agility
ArcWorld workcells have integrated safety features, including protective enclosures, safety without the need for the heavy- Pre-engineered robotic welding
interlocks and advanced sensing technologies. duty support. workcells, like ArcWorld cells with

OCTOBER 2024 37
the new RM2 Ferris wheel-style wheel-style positioners offers a robust
positioner, represent a significant solution that can elevate production
leap forward in welding technology capabilities, ensuring safety, reliability
and accessibility. These systems and efficiency in today’s dynamic
offer measurable benefits in manufacturing environment.
safety, reliability and efficiency.
By incorporating advanced
safety features, ensuring reliable
performance and optimizing
production efficiency, these systems
address the key challenges faced by
modern manufacturers.

The positioner, with its modular

design and multiple payload
capacities, further enhances the
versatility and functionality of
robotic welding systems. It enables
manufacturers to handle a diverse
range of components and adapt to
varying production demands, making
it a valuable addition to any welding
operation looking to automate.

As the welding workforce shortage

continues to grow and industries
increasingly adopt automation,
understanding these benefits can
guide company owners in making
informed decisions. The combination
YASKAWA AMERICA INC.
of ArcWorld workcells and RM2 Ferris
by John Trengove, head of marketing design,

Productive Robotics Inc.

Laser
launch
A new laser welding cell –
designed and built in America –
makes its market debut
 W
elding dramatically faster welding with
cobots are exceptional ease of use.
in increasing
demand to FEASIBLE FEATURES
help welders To get fabricators up and running in
and businesses short order, the Laser Cell is turnkey
safely increase productivity and and simple for any size shop to set up
repeatability and improve weld quality – out of the box – without the need for
while also removing the mind-numbing third-party integrators. Alexia Perry,
task of repeated production welding vice president of Rocker Industries, a
for welders that are increasingly hard provider of defense, aerospace and
to come by. Among those new cobots commercial solenoid and solenoid “The ease of setup was
is the Blaze Laser Cell, a fully enclosed, valve solutions, explains. huge. We knew our team
standalone, automated laser welding
solution that doesn’t require a laser “It really felt like Productive Robotics could completely set up
darkroom. This new market entrant was more of a partner for us,” Perry and have no issues.”
is the latest addition to Productive says. “Also, the ease of setup was huge.
Robotics Inc.’s comprehensive and We knew our team could completely
Alexia Perry, vice president, Rocker Industries
expanding line of cobot welders, all set up and have no issues.”
engineered from the ground up and
built in America. And once it’s ready to go, it features
helpful technologies, such as the
Understanding the workload of company’s proprietary Blaze Vision
today’s fabricators, the Blaze Laser Live Video so that operators can
Cell handles both small-batch and monitor the welding in progress in
high-volume jobs. Built around the real time from two views without the
high-performance, zero-programming need for welding visors, goggles or
Blaze cobot the company is known for welding screens.
plus the industry-leading LightWeld
laser system from IPG Photonics Additional features include active
Corp., the Laser Cell combines fume extraction for operation in most
environments with easy ducting away the complexity of a typical laser
from the operator and workers nearby. welding cell. Benefits of laser
Further assisting operators is the Laser welding include the lasers’ low heat
Cell’s unrestricted access to the large- input and ability to join metals of
format weld table, making loading and different thicknesses, creating high-
unloading easy and ergonomic. Built-in strength joints while using minimal
bright LED lighting also fully illuminates or no consumable wire. According
the job at hand, reducing any strain on to a representative from Associated
the eyes for job setups and fixturing. American Industries, a company
out of Allen, Texas, that provides
IN ACTION equipment solutions to food service
The Laser Cell only needs minimal and retail industries, laser welding
setup to be ready to give fabricators also improves the speed and quality
the benefits of laser welding without of welds.

Productive Robotics’ Blaze Laser Cell features unrestricted access to the large-format work
area with LED lighting and active fume extraction.
 “The Blaze laser let us replace thousands NO PROGRAMMING
of spot welds with continuous laser No matter the bells and whistles,
welded seams,” the rep says. “This is a if a welding cell isn’t easy to use,
faster process that completely seals the it’s essentially useless. That’s why
parts instead of just connecting them.” Productive Robotics focused on
eliminating programming with the
Materials up to 1/4 in., including steel, introduction of its teach-by-doing
aluminum, copper, titanium and nickel technology in 2017 – the first of
alloys can all be laser welded. And its kind. The innovation radically
that includes thick, thin and reflective simplified the way fabricators work
metal welds that are finished without with cobots as the cobot line of
distortion, deformation, undercut or welding cobots learns entirely by
burnthrough, which reduces secondary doing. In other words, operators
machining or the need to straighten physically move the torch to show the
parts deformed by high heat input. cobot the start and end of welds, tack
points, circles or any complex shape at
The IPG LightWeld 1500 is included the touch of a button.
as standard with the Blaze Laser
Cell, but it can also be ordered with Anyone can teach the Blaze cobot to
optional pre- and post-laser cleaning weld a new job in matter of minutes,
capabilities (up to a 15-mm cleaning typically in less time than it would
path), allowing operators to switch from take a welder to do manually. Once a
laser welding to laser cleaning with an welding job is set up, the production
easy and quick nozzle swap. The boost run moves many times faster than
in capability, speed and quality, plus manual welding. Subsequently, the
the empowerment of welders at all skill cobot will also remember the job
levels to do more, with less rework, for future runs, further speeding up
means fabricators can start realizing the time to process a job. All welding
productivity gains up to five times details and recipes are easily set on
Direct video monitoring of welding, in progress from two views, displayed on two Blaze compared to traditional methods from the tablet controller with drag-and-
Vision monitors. Welding visors, goggles or welding screens are not required. day one. drop simplicity.

OCTOBER 2024 42
 “We save significant time and
money while increasing quality
and precision.”

Timo Lunceford, general manager, Swiss Productions Inc.

Furthermore, there is complete control at Swiss Productions Inc., a precision

and customization of weld parameters, screw machine shop out of Ventura,
weld recipes, weld types and selection Calif.
of all IPG laser welding and cleaning
presets. The built-in factory presets for THE 7-AXIS ADVANTAGE
welding and cleaning reduce learning When it comes to welding
curves, making overall training fast maneuverability, Productive Robotics’
for new operators and experienced 7-axis Blaze cobot is unmatched.
welders alike. Thanks to its seven axes, the robotic
welding system can move in and
“We save significant time and money around obstacles, such as a workpiece
The Laser Cell provides continuous, aesthetic, high-speed welding across a range of materials, while increasing quality and precision,” fixture, while steadily maintaining
including steel, aluminum, copper, titanium and nickel alloys, in a range of thicknesses. says Timo Lunceford, general manager the torch’s position. Standard on all

OCTOBER 2024 43
 FIND THE
PERFECT STAFF
Job seekers on [Link] want to work for companies
like yours. Post your job listing today

It's as easy as copying and pasting the URL where your jobs
are currently posted into the link below.
We'll handle the rest.
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opportunities the industry has to offer.

No programming is required and all welding details and recipes are easily set on the tablet
Explore [Link] today
controller with drag-and-drop simplicity.
 Blaze cobots, the 7-axis reach saves priced solution is for shops not only
fabricators time and money by allowing looking to boost productivity, stay
welders to get more weldments done competitive and ship on time, but
in a single setup, versus having to to keep current, attract early entry
re-fixture with the more-common welders and showcase leading edge
6-axis cobot. capabilities to customers.

To appreciate the benefits, it’s helpful

to know that the human arm has seven
degrees of freedom from the shoulder
to the hand. A welder uses all that
natural freedom to manipulate the
torch where needed. Having a cobot
with that same capability as welders
made a lot of sense to the engineering
and welding teams at Productive
Robotics. And, while many 7-axis
industrial robots require safety cages,
Productive Robotics is currently the only
U.S. company to provide 7-axis cobots
that work safely alongside humans.

Productive Robotics’ Blaze range of

cobot welders are all laser-focused
on solutions for production efficiency,
strengthening teams, cost control and
labor challenges. The company brings
expertise in robotics, welding, and
light safe enclosures all to bear in the
The 7-axis Blaze cobot can move in and around obstacles, such as a workpiece fixture, while engineering of the Blaze Laser Cell with
PRODUCTIVE ROBOTICS INC.
steadily maintaining the welding torch’s position. IPG LightWeld lasers. This affordably

OCTOBER 2024 45
by Jimmy Myers, senior editor

SIZEABLE
SAWING
When extra engineering is required for a
10-ton automatic bandsaw, a sawing equipment
manufacturer steps up to the plate
T
he Kasto booth received especially in the South, use saws this
its fair share of visitors size to handle that 38-in. to 41-in. tube
at the 2024 International that may be buried underground for oil
Manufacturing Technology and gas.”
Show – IMTS. Kasto featured one of its
larger saws, the Kastowin A 10.6, an Stefan Dolipski, vice president at Kasto,
automatic bandsaw weighing more adds that large saws like the A 10.6 are
“A lot of big line tubing houses,
than 10 tons, standing nearly 12 ft. a good match for manufacturers that especially in the South, use saws
tall and 16 ft. wide that uses a 34-ft. cut large blocks. “It’s a niche market,”
saw blade. he notes. this size to handle that 38-in. to
The A 10.6 brought curb appeal to With a saw this large, the designers had
41-in. tube that may be buried
the German-based sawing company’s to consider how it would be shipped underground for oil and gas.”
booth, but the engineering behind from where it is produced in the north
such massive machines is equally Black Forest town of Achern, Germany, Jay Smith, regional sales manager, Kasto
impressive. Available since 2015, only a Kasto’s headquarters. Dolipski says
handful are in use in North America. the initial thought was that customers
would prefer for the saw to be shipped
Jay Smith, regional sales manager at in one piece, unloaded and ready to go,
Kasto, says the A 10.6 is generally used which required some extra planning.
in steel distribution warehouses where With only a couple pieces dismantled,
cutting 32-in. to 41-in. bar or cutting they were able to achieve that, as it fits
larger materials down to wafers for in an open shipping container. the ability to cut with precision is use “every tool available” to find areas of
customers to machine is the norm. compromised, the life of the saw blade the saw that can be improved.
DAMPENING VIBRATION is shortened and the finish quality is
“That’s really where this machine comes The main culprit all saw manufacturers negatively impacted. In the design “In the development of a saw,” he says,
into its wheelhouse,” he says, adding work against is vibration, and that phase of the saw, computer modeling “we want to pick up any noise, any
that it also processes large-diameter is true even in massive saws like the was used to detect flex in the machine vibration that we find. We use sensors
tubing. “A lot of big line tubing houses A 10.6. When a saw vibrates in excess, body, Dolipski says, adding that they and microphones to gather the data

October 2024 SP47

 Structural Sawing
to find out where the vibration is
the heaviest.”
“Now, we use a more robust steel
structure,” he says, adding that using
Requires TENACITY
heavier linear band guides allows the
Dolipski says that in the “old days,” saw transfer of vibration out of the saw head
manufacturers would fight vibration and into the frame where it has less
by adding weight, sometimes going as of an impact on cut quality. “And, we
far as filling in areas of the saws with a design the steel frames with the mindset
polymer concrete. of having the vibration pulled into

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BAND SAW HACK SAW POWER TOOL HAND TOOLS

BLADES BLADES ACCESSORY BLADES
the ground. With these machines, we stubby chip is usually an indication that
highly recommend bolting them down vibration is impacting the quality of
because that will provide the circle loop the cut. Unhealthy chips can also be an
of all the vibration being transported to indication of the speed and feed rate
the ground.” being incorrect, which means the blade
is grinding against the material instead
HEALTHY CHIPS of cutting into it. Regardless of the
Whether it is a small bandsaw or a health of the chips, getting them out
large one like the A 10.6, the material of the way of the blade is essential.
removed by the blade (the chips) can
tell a story. A “healthy” chip is one where Many saw manufacturers offer
the material is coil shaped. A short and a coolant option that is sprayed

The oversized chip brush is just one of multiple components that keep chips
from binding between the blade and the workpiece being cut.

into the cut area in mist form or require some technology to keep
distributed in higher volume, called them out of the way of the blade.
flooding. Coolant keeps the blade
from overheating, but also helps Coolant will flow through the cut
in washing out the chips. One channel, but an air assist sitting
advantage in regard to chip removal on the blade guide and pointed
The spindle in this chip trough moves the chips away from the saw and into in a large saw is that larger chips into the cut channel provides extra
a bin. are easier to remove, but they still oomph to remove chips, according

October 2024 SP49

 V-1822
to Smith. It can also keep the blade so halfway through you don’t want MANUAL VERTICAL
guide chip free. those chips piling up causing undo TILT FRAME BANDSAW
wear and tear on the blade.” Capacity: 18" x 22"

“Every 30 sec., we pulse a blast

of air through that cut that helps Another difference in such a large
remove excess kerf chips building saw compared to smaller ones is the
up in there,” he says. “That’s A 10.6 is equipped with a spindle in
especially important on a large cut. a trough below the cutting area that
Depending on the grade, cutting a carries the chips away from the saw
38-in. workpiece may take an hour, and into a collection bin.
USE OUR ONLINE SAW SELECTOR
TO HELP YOU FIND THE RIGHT SAW
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“In the development of a saw, we
want to pick up any noise, any SWAPPING BLADES ladder and, after opening the safety
vibration that we find. We use When the time comes to switch out cover, they can access the blade. A
the bandsaw blade, whether it is worn switch disengages hydraulic clamping
sensors and microphones to gather and due for replacement or because a on the blades and the operators can
different material requires a different pull the blades down and away from
the data to find out where the type of blade or tooth geometry, the band guides, move the entire blade
vibration is the heaviest.” the process of switching out the out and install a new one.
34-ft. blade is surprisingly not that
Stefan Dolipski, vice president, Kasto difficult, aside from the fact that it is
recommended that two people are
involved in the task. Saw operators can
KASTO
reach the band wheels via a three-step

October 2024 SP50

by Jimmy Myers, senior editor

IMPLEMENTING
AUTOMATION
New robotic material handling
and cut list automation for sawing
operations gives customers the
efficiency they need
S
aw technology changes in operators in our industry seem to be a
subtle ways, as the age-old huge turnover position. It’s very hard
process of running a blade to find those 10-year saw veterans that
through material can only know the saw like the back of their hand.
be enhanced so much. But as saw Having automation that can combat that
manufacturers tweak their offerings to is something we’re confident will help.”
make their machines easier to operate
and more efficient and productive, they Peterson says the initial idea to bring
are also invested in bringing material robotic material handling into the
to the saw and automating the method mix with Cosen saws came from Kent
through which cut parts are offloaded. Hughes, the company’s vice president
“We’re trying to partner with a lot
of sales and marketing.
Understanding those needs, Cosen more integrators that can add to
Saws recently unveiled a new robotic “Kent is in the field constantly – he’s
offloading system. At the 2024 in the workplaces,” Peterson says. the saw’s overall efficiency and
International Manufacturing Technology “He’s hearing the feedback and what make user error less of a thing.”
Show – IMTS, those who visited the needs are. When he’s talking to a
McCormick Place’s north building might lot these people in the field, the one
Hayden Peterson, marketing manager, Cosen Saws
have gotten a look at the system in thing he keeps hearing is the need for
action. It consists of a robot that utilizes automation integration. It got to the
magnetic end-of-arm tooling that picks point where he said, ‘this is something
up parts off the saw table and deposits we need to pursue.’”
them in bins.
During the demonstration at IMTS, the
“We’re trying to partner with a lot more robot picked up 2-in. steel solid rounds
integrators that can add to the saw’s off Cosen’s flagship bandsaw, the G-320.
overall efficiency and make user error The weight capacity on this robot model
less of a thing,” says Hayden Peterson, is 15 lbs. Peterson says the magnetic
marketing manager at Cosen. “Also, device at the end of the robotic arm was

October 2024 SP52

 a good choice for this application as it “It could be 100 different programs
offers a less intrusive method of picking based on the different material sizes,”
up parts. Bryan says of the programming
that is adaptable to just about any
“You can go to scale where the arm type of job. “The programming is
comes in and the grabber clamps onto material-specific and size-based.
the material and moves it,” he says of Once the robot fills up that bin,
customizing for the removal of larger the operator comes and takes the
parts in different applications. material away.”

ROBOTIC ASSISTANCE Peterson adds that in some facilities,

Cosen outsourced the robot for the an operator will manage multiple
material handling, choosing ACT saws at the same time. Having the
Robots Inc., based in Bristol, Conn. robot manage the material handling
ACT produces a dozen or so handling means there is a “lot less material
and general robots in 4- and 6-axis the operator has to pick up,” he says,
models and also produces two welding which reduces physical strain.
robot models.
There is also the safety component.
Tyson Bryan, sales specialist at Cosen, While many saws today include
says the robot is programmed to identify safety mechanisms that make it
exactly where parts are located on the difficult for an operator to put
saw table, then pick up a part and drop themselves in danger, having a robot
it in a dedicated bin or space within the pick up the parts coming off the saw
bin. During the IMTS demonstration, blade basically eliminates the risk
a square plastic bin was segmented of injuries. To ensure the robot is
into 20 sections and the robot was not damaged, it is programmed to
Cosen Saws displayed its new robotic material handling solution at IMTS in
Chicago, offering a demonstration of how accurately solid rounds of steel could programmed to drop a specific number engage only when the blade is up,
be picked up from the saw table and deposited in specific bins. of parts in each section of the bin. stopped and away from the table.

October 2024 SP53

The material offloading feature is
currently being sold as an add-on to the
G-320, but Peterson says the plan is to
CUE THE QR CODE
Another automated integration Cosen
recently released is a QR code reader
SAW CITY
The largest sawing showroom in North America

integrate it with other fully automatic called Q-Cut that should significantly
saws in Cosen’s line. reduce operator error and ensure more
efficient cutting.
“With what we’ve already been able to
achieve with the G-320,” he says, “it’s A project manager simply accesses the
going to be very easy to translate that to Q-Cut dashboard on a desktop computer
all of our larger production machines.” to generate job orders and create the

By utilizing Q-Cut, a QR code reading solution, saw operators have their cut
Behringer Saws (610) 286-9777
[Link]
lists automatically sent to the saw, reducing user error, waste and time. Home to our full line of band saws and circular cold saws,
as well as our fully staffed parts and service departments.
Our fabrication and design teams are also ready to help with
all of your material handling and automation requirements.
parameters for each application, which the saw for even more automated
includes material type and thickness, features related to loading material.
angle, length and number of cuts, Yu-Hsien Ho, director of channel
among other information. The work sales and marketing at Cosen, says
order is then created and associated the system features a 3-degree
with a unique QR code, which the inclined loading area with a simple
operator reads with their scanning four-step lift-and-load configuration
gun at the saw. The cut list is then via hydraulic cylinders and
automatically uploaded to the saw. cam actuator. “Employers want to reduce
Peterson says the Q-Cut technology, To reduce impact and dampen workplace injuries, and the best
which is powered by Cosen’s software, the sound of material loading,
Mechalogix, vastly improves workflow mechanical and cushioned stoppers
way to do that is to automate the
and saves on costly scrap. are located throughout the table. process as much as possible to
An integrated PLC and handheld
“As soon as the operator accidentally remote control allow workers to limit the touch points between
types in wrong information,” he says operate the loader independently
the operator and the material.”
of the traditional method of manually or in synchronization with the
entering cut list information at the saw, bandsaw machine.
“you have a full job where the material Yu-Hsien Ho, director of channel sales and marketing,
gets wasted. The robot is running and “In addition to its automatic loading Cosen Saws
grabbing that material, which is the feature,” Ho says, “when multiple
wrong material, so that is a lot of man bars are required for production,
hours, power and resources that are the loader also works as a regular
wasted because of one little mistake.” steel roller table with solid machined
rollers spread out evenly to facilitate
AUTOMATED LOADING smooth material feeding up to the
Cosen is developing a material machine’s intended capacity of
handling system at the other end of 12.7 in. by 14.9 in. wide.”

October 2024 SP55

Ho says Cosen has experienced a
surge in demand for automation ever
eliminates the need for saw operators
to measure material by hand and allows
V-18APC-60
AutomAtiC VertiCAl BAnd SAw
since the global pandemic when them to easily process unwanted trim
the labor shortage began to really or make their desired first cut. our AffordABle, high quAlity SAwS Are unmAtChed 18” x 22” CAPACity
impact manufacturers. He mirrors in ProViding the BeSt CoSt-Per-Cut on the mArket 7.5 hP Vfd
1 1/4” BlAde
what others at the company have Ho says intelligent material remnant
The V-18APC-60 is a automatic vertical band saw with the
said about the automated features management can also detect the back ability to miter from 60° left to 60° right. You can choose a left • AutomAtiC ProgrAmmABle mitering
or right side infeed. A 3 degree fixed canted head allows for • four full Stroking hydrAuliC ViSeS
becoming “inevitable.” end of the material, “maximizing the more efficient cutting and improved blade life when cutting larger • AutomAtiC multi-indexing
use of remnant before out of stock, beams, structural steel, and bundles of square tubing. • Powered moVeABle guide Arm

“Another factor is safety,” Ho says about and ejecting the remnant to the front
the increase in automation. “Employers discharge table when a new bar is
want to reduce workplace injuries, and available and loaded into position.” He
the best way to do that is to automate also mentions that due to clamping
the process as much as possible to limit and coolant mechanisms on the loader,
the touch points between the operator operators can load multiple bars and
and the material. With the loader set the saw to cut all the material.
feeding into the saw for cutting and the
robot on the outfeed side taking cut “The operator only has to worry about
pieces and palletizing it, the operator making sure the loader is filled with
only has to be responsible for loading material,” Ho says. “If a customer has to
material and moving the cut and cut 1,000 pieces of 2-in. round material
palletized material downstream for the at a certain length, this complete
next process.” system will save them a lot of time and
frees up the operator to take care of
Another perk with the automated other items downstream.”
loader is the automated “First Cut”
feature, which is Cosen’s technology
that automatically detects the front
edge of a piece of material. This COSEN SAWS
reliABle SAwS. reliABle PeoPle.

[Link]
 Fronius USA
hgg
TRADE SHOW

Showcase hsg

lantek
ipg photonics

jpt
Abicor Binzel
Mazak Optonics
Amada America Inc.
Richardson Electronics
American Welding Society Soitaab

Stamtec
Behringer saws
CINCINNATI INC. The L.S. Starrett Co.
Trumpf

cosen saws yaskawa

davi
ABICOR BINZEL is a global leader in welding technology
solutions. With a rich heritage dating back to 1945,
we specialize in the development and manufacture
of advanced welding torches, consumables, and
accessories. Our innovative products cater to a
LEARN MORE
diverse range of industries including automotive,
shipbuilding, construction, and manufacturing. With a
relentless commitment to research and development,
we continuously strive to enhance the performance,
durability, and ease of use of our products. Our team
of skilled engineers and technicians work diligently
to develop cutting-edge solutions that improve
productivity, reduce downtime, and ensure the highest
welding quality.
Since its inception, AMADA AMERICA, INC. has provided
manufacturers with innovative, productivity-enhancing
sheet metal machines, including fiber lasers, turret
punch presses, combination machines, press brakes,
automation systems, and software. We accomplish this
LEARN MORE
by carefully listening to the voice of our customers and
engineering machine solutions that cater to their sheet
metal fabrication needs. Additionally, AMADA supports
its customers with high-tech facilities throughout
the U.S. that offer custom machine demonstrations,
advanced technical training, and R&D for new
manufacturing processes.
Founded in 1919, the American Welding Society is a
nonprofit organization with a global mission: to advance
the science, technology, and application of welding and
allied joining and cutting processes worldwide, including
LEARN MORE
brazing, soldering, and thermal spraying. By fostering
knowledge, embracing change, and providing real-world
opportunities through scholarships, fellowships, and
workforce development, AWS provides the tools to help
members succeed—and to inspire future generations of
welding professionals.
BEHRINGER SAWS is a manufacturer of high-
performance bandsawing machines, circular cold
saws, and structural fabricating equipment. We
pride ourselves on building the highest quality metal
sawing and fabricating equipment in the world. LEARN MORE
Our goal is to create value for our customers by
continuously striving for the highest levels of speed,
accuracy, and cost-effectiveness. All equipment
design is based on achieving a dependable and
long-lasting machine, and in that regard BEHRINGER
is truly the benchmark. Additionally, BEHRINGER
offers the widest selection of models, allowing us
to not oversell or undersell a customer’s needs and
requirements for each unique application.
Cincinnati Incorporated (CI) is a U.S.-based, build-
to-order machine tool manufacturer with over
125 years in the industry. Our engineering and
manufacturing expertise makes us the ideal partner for
companies building innovative products that demand
extraordinary durability, stability, and industry-leading LEARN MORE
features. At our state-of-the-art, Ohio-based facility,
we develop and build custom software, dependable
laser cutting systems and automation equipment as
well as metal fabrication equipment, including press
brakes, shears, welders, and PM presses. Our extensive
knowledge puts us in a unique position to help you
drive efficiency in your manufacturing process no
matter how simple or complex.
Founded in 1976, Cosen Saws has grown into one of
the world’s premier band saw manufacturers, boasting
an extensive product line and a global sales network.
Cosen is committed to delivering dedication, quality, and
service, a mission that has helped earned the company
the top spot among all sawing manufacturers according
LEARN MORE
to Metal Center News. In 2024, Cosen celebrates its
third consecutive year receiving this prestigious honor,
further strengthening its commitment to excellence.
The company’s North American offices and warehouses
are located in Charlotte, NC. From there, the company
provides an extensive selection of service replacement
parts and local machine technicians. Cosen’s warehouse
inventory contains over 150 new machines in stock, of
which include a variety of styles and material capacities
which help meet various industry demands.
Davi Inc, the North American branch of the Davi Group, is
the world’s largest manufacturer of plate rolls, angle rolls,
and custom rolling machines. Founded in Italy in 1966,
LEARN MORE
Davi leads the industry in sales, production, patents, and
innovation. To support North American customers, Davi
Inc was established in 2002, now based in Dallas, TX With
a network of over 100 global dealers and four logistics
centers in North America, Davi focuses on customer
service, engineering custom solutions, and continuously
innovating to meet future industry needs.
Fronius is the innovation leader for arc welding. We LEARN MORE
offer solutions for manual MIG, TIG and Stick welding
in addition to our leading edge technology for robotic
and automated applications. Our tailored solutions and
customer service create lasting partnerships.
HGG Group Profiling Equipment’s commitment to
offering customers the freedom to create is evident
in the quality 3D profiling machines that provide
complete flexibility to cut complicated profiling in
LEARN MORE
steel pipes, beams, box sections and other profiles
regardless of size and specifications. Founded in 1984
in Wieringerwerf, Netherlands, HGG Group has become
the world leader in steel profile cutting with expertise
gleaned from years of subcontracting 3D profiling
services which typically handle roughly 250 tons of
material per week. The company’s machines can cut
every type of steel, with the exception of plate, and are
found in nearly every type of shop.
HSG is a global leader in metal shaping equipment
and automation solutions. With over 25,000 machines
installed worldwide and a workforce exceeding 1,800,
HSG is a trusted partner across various industries.
Central to HSG’s success is its commitment to LEARN MORE
innovation and reliability. The company delivers
professional and cost-effective machinery. It has also
positioned itself as a growth partner for customers,
offering tailored solutions that address the evolving
demands of modern manufacturing. This customer-
centric approach is reinforced by a global network of
R&D and manufacturing facilities, including an R&D
center in Tokyo, Japan, and major production bases
across China and Thailand.
IPG Photonics Corporation is the leader in high-
power fiber lasers and amplifiers used primarily in
materials processing and other diverse applications.
The Company’s mission is to develop innovative
LEARN MORE
laser solutions making the world a better place. IPG
accomplishes this mission by delivering superior
performance, reliability and usability at a lower total
cost of ownership compared with other types of lasers
and non-laser tools, allowing end users to increase
productivity and decrease costs. IPG is headquartered
in Marlborough, Massachusetts and has more than 30
facilities worldwide.
Registered in 2006, JPT is focusing on the R&D,
production, sales and technology service of optical fiber
devices, lasers and laser intelligent equipments. After
years of development, JPT has an international R&D
LEARN MORE
team, global marketing platform and serves for many
well-known customers in Asia, North America, Europe
and etc. Based on laser technologies, JPT integrates
leading technologies such as laser and optics, test
and measurement, motion control and automation,
machine vision. The company highly values intellectual
property and has applied for more than 700 patents.
Lantek is a multinational company leading the digital
transformation of companies in the sheet metal and
metal industry. With its patented manufacturing
intelligence software, Lantek enables factories to be
LEARN MORE
connected, turning them into Smart Factories. Lantek’s
CAD, CAM, MES, and ERP solutions are developed for
manufacturers of metal parts from sheet metal, tubes,
and profiles using any cutting technology. Founded in
1986 in the Basque Country (Spain), Lantek has more
than 32,000 customers in over 100 countries and 21
offices in 15 countries and an extensive network of
distributors with an international presence.
Mazak Optonics, a leader in laser technology, offers
a comprehensive range of 2D and 3D laser-cutting
machine models for the metal fabrication and structural
steel markets. This innovative range of products
LEARN MORE
enables Mazak to better meet fabricators’ specific
laser application needs while significantly improving
production efficiency, competitive positioning, and
profitability. Mazak utilizes innovative engineering and
intelligent automation to simplify operations and deliver
more consistent machine performance. Mazak Optonics
supports the North American installation base from its
headquarters in Elgin, IL.
Richardson Electronics provides Original quality laser
parts and consumables, without the Original prices
for Trumpf®, Bystronic®, and other leading laser
manufacturers. Our products are manufactured to
meet or exceed the OEM quality standards while
maintaining the same form, fit, and function all at highly LEARN MORE
competitive prices. Richardson Electronics is a global
company. We carry local inventory, and our logistics
capabilities enable us to quickly ship products to any
location, assisting customers to maximize machine
uptime while reducing cost of operation. Our superior
quality parts, outstanding selection, and competitive
pricing make Richardson your number-one source for
laser spare parts.
Since 1938 Soitaab has been a premier provider of metal
fabrication equipment. With a long history of innovation
and industry firsts, Soitaab has always maintained a
customer-focused approach. From simple plug-and-play
systems to highly engineered multi-process machines for
LEARN MORE
shipyards and steel service centers, Soitaab can provide
the right solution. Our complete product range of
plasma, oxy-fuel, waterjet, and laser cutting equipment,
allows us to match the right technology to every
fabrication requirement. Through using this equipment
in our own steel service center, Soitaab has a unique
understanding of our customers’ businesses and their
most demanding challenges.
Stamtec is one of the largest press builders in the world,
with more than 60,000 presses sold; 1500 employees;
6,500,000 square feet of facilities worldwide, producing
more than 3,000 presses per year. * One of the largest
in-stock inventory of mechanical and servo presses in
LEARN MORE
North America * Manufactured by our own employees
in our own factories, since 1949 * Electrical/mechanical
engineers, project management/sales application,
service/support from our 72,000 sq. ft. facility near
Nashville, TN * Complete turn-key integration of press,
quick die change, coil feedline, transfer system and
other peripheral equipment * Competitive pricing for a
well-built, high-performance product
Founded in 1880 and headquartered in Athol, MA
U.S.A., The L.S. Starrett Company is a leading global
manufacturer of band saw blades, precision measuring
tools and gages, optical comparators, vision systems
LEARN MORE
and force and hardness testing solutions. Starrett also
manufactures laser measurement systems, custom
engineered granite solutions, custom gaging, power tool
accessory saw blades, workshop tools and jobsite tools.
Skilled personnel, superior products, manufacturing
expertise, innovation and excellent service/ support
have earned Starrett its reputation as the “World’s
Greatest Toolmakers”.
TRUMPF is the world market leader in sheet metal
fabrication equipment and industrial laser technology.
LEARN MORE
Products manufactured with the company’s technology
can be found in almost every sector of industry.
TRUMPF Inc. is the largest subsidiary of the TRUMPF
Group and is dedicated to serving the U.S., Canadian
and Mexican markets. Additional company information
is available at: [Link]
Yaskawa Motoman is a leading industrial robotics
company in the Americas and provides automation
solutions for virtually every industry and robotic
application. With our comprehensive line of robots,
integrated power sources, peripherals, and family of LEARN MORE
fully integrated welding cells, we provide reliable, low-
risk solutions. For integration support, tap into our
partner network or our in-house engineers. Combine
that with our renowned service and training, Yaskawa
Motoman stands alone as the best partner to ensure
success in your next robotic project.
 Lasers & Plasma

Fabtech Fiber laser cutting

AMADA AMERICA INC. will feature the North American debut of

2024
the Regius 3015 AJe linear fiber laser. The Regius Series combines
a 3-axis linear drive system with a variety of autonomous features
to ensure high-speed, continuous operation. Other highlights
will include the Ventis 3015 AJe fiber laser paired with AMS CL automation and TKL automated
parts sorter. This system uses AMADA’s Locus Beam Control to achieve infinite locus patterns to

Preview
ensure optimum beam shape control for each specific cutting application with 24/7 processing
capabilities. Another highlight will be the FLW ENSISe M1 fiber laser welder (FLW), a complete
welding solution equipped with a unique processing head and offline programming capabilities.

AMADA AMERICA INC.

Booth No. S22003

Laser solutions
IPG Photonics Corp. will showcase
innovative laser solutions. Attendees
can experience handheld laser welding
first-hand with LightWeld handheld laser
welders, as well as check out demos of the
brand-new LaserCell 2000 robotic laser
North America’s largest metalforming, fabricating welding and finishing event, cleaning system. IPG will also demonstrate
Fabtech, heads to the Orange County Convention Center, Oct. 15-17, 2024. rapid laser curing of powder coat and
The show provides a convenient one-stop venue where visitors can meet with advanced vision alignment technology for
1,500-plus world-class suppliers, discover innovative solutions and find the tools high-accuracy laser cutting.
to improve productivity and increase profits. There is no better opportunity to
network, share knowledge and explore the latest technology. Attendees will gain
insights into industry trends that will help prepare them for what is ahead. IPG Photonics Corp.
Booth No. W3628

October 2024 78
Fiber laser cutting Laser beveling
Mazak Optonics Corp. will feature the new Optiplex 3015 TRUMPF Inc. will show a new laser cutting machine
Ez 6 kW. The 2-D fiber laser cutting machine integrates that automatically prepares parts for welding. The
Mazak’s NEO design into an affordable, entry-level TruLaser Series 3000 Bevel Cut Edition can produce
processing solution. Features include an auto-focus torch, beveled cutting edges on the top and bottom edge of
large front and side access doors, Mazatrol SmoothLx the component while cutting. This ensures optimum
control, and other intelligent, efficient functions. Also on preparation of the welding edges and reduces
display will be the Optiplex 4220 NEO 20 kW and Smart Cell 6-axis robotic loader and part sorting downstream processes. The machine can apply chamfers to sheets of up to 1 in. thick. The
system. The 4220 machine ranges in power levels from 4 kW up to 20 kW to accommodate high- machine is particularly suitable for mild and stainless steel. Using this machine, manufacturers
power cutting of larger material. The Smart Cell utilizes interchangeable magnetic and suction cup have a particularly productive universal machine with which they can integrate downstream
grippers to load material and sort laser cut parts. process steps into laser machining.

Mazak Optonics Corp. TRUMPF Inc.

Booth No. S20085 Booth No. S18003

Laser cutting & software Tube & 2-D laser cutting

Cincinnati Inc. will highlight its latest laser cutting, welding and press BLM GROUP will demonstrate the LT7 tube laser
brake technology along with related automation, including the CLX system for processing tubes ranging from
fiber laser. CI will hold daily demonstrations throughout the event 12 mm to 152 mm in diameter and up to 23 kg
showing the life cycle of an assembly. This includes issues that a per m in weight. Every diameter adjustment is
production facility might typically face along with how the software fully automated and even sections with an “L,”
can pivot to address these issues. CI’s Encompass software suite “U” or other open profile and flat bars are standard jobs, all processed in a fully automatic mode.
bridges the gap between digital designs and physical components The LS7 laser cutting system, newly available with 20-kW laser power, is a 2-D fiber laser cutting
enhancing productivity and efficiency from start to finish. From the initial unfolding, through system that excels in processing a variety of metals such as stainless steel, iron, aluminum and
nesting, cutting, bending and monitoring the machine’s overall health, Encompass seamlessly copper. This versatile machine seamlessly integrates into production lines, harnessing the benefits
covers these critical aspects of transforming digital designs into tangible parts efficiently. of fiber lasers, like reduced energy consumption and minimal maintenance.

Cincinnati Inc. BLM GROUP

Booth No. S13085 Booth No. S22061

October 2024 79
Plasma cutting Laser cutting
HGG Group will exhibit its RPC 1200 Mk3 HSG Laser will show its new flagship GV Series
plasma beam coping solution. Experts will laser cutting machine, which is designed to
be available to discuss the machine and the provide an efficient, reliable and smart sheet
RoboRail robotic plasma cutting machine and metal cutting solution. It has up to 60-kW
other automated metal cutting technologies. laser cutting capacity, 300 m per min. linkage
The RPC 1200 Mk3 is capable of cutting any type of pipe profile, including profile beams, angle bar, dynamic performance, a new reducer and
channel, square tubes, pipes, plates, T-bars and bulb. The RoboRail reduces profile cutting time by a new machine bed. The machine has been
up to six hours in some applications, including pipe for railings, channels and other miscellaneous designed to be dynamic and efficient and has been upgraded for precision and accuracy. The
parts. The compact robotic machine’s ability to take designs directly from 3-D SDS/2, TEKLA, STEP versatile automation features are intelligent and easy to use. These features combine to greatly
and other CAD files ensures the most accurate cutting performance. improve comprehensive production efficiency and achieve manufacturing efficiency.

HGG Group HSG Laser

Booth No. S24177 Booth No. S13003

Laser measurement Manufacturing software

MKS Ophir will show a range of laser measurement systems that help users Lantek will showcase its latest CAD/CAM and
understand the behavior of high-power lasers in industrial environments. MES/ERP solutions. Visitors will learn about the newest
Ophir Ariel is a robust, ultra-compact laser power meter for measuring features and technologies within Lantek Expert, the
high-power industrial lasers to 8 kW; no water or fan cooling needed. EdgeLine Bevel and Flex3D functions, which will also
Ophir BeamWatch is a non-contact beam monitoring system that provides be highlighted. The EdgeLine Bevel feature for Lantek
simultaneous measurements of multiple profiles along the beam caustic, Expert Cut CAD/CAM nesting software is designed to
and real-time focal shifts. Designed for manufacturers and users of laser-based cutting and streamline the CNC programming of modern TRUMPF cutting machines, providing a more efficient
welding machines, Ophir IPM-10KW is a high-power modular laser power sensor for high accuracy and simplified process. The technology offers several key advantages over traditional methods that
and repeatable measurements in dusty, dirty production environments. It measures powers 100 W allow specific beveling techniques to be performed without tilting the laser head, reducing overall
to 11 kW for wavelengths 900 nm to 1,100 nm and 10.6 microns. processing time and eliminating the need for separate work center processes.

MKS Ophir Lantek

Booth No. S18120 Booth No. S17017

October 2024 80
Laser welding Laser cutting &
Laser Mechanisms Inc. will display the FiberWeld DHµ, which is an ultra- automation
compact laser wire direct-energy deposition head for processing large-scale Bystronic Inc. will present the 30-kW
industrial parts, aerospace components and tooling. Engineered for high ByCut Star 3015 fiber laser with a new
duty cycle production applications, the machine features direct-cooled system for loading and unloading
reflective optics and transmissive optics. Compatible with most hot-wire flat sheet materials. Also, the 4-kW
systems, the machine allows filler wire to be fed directly into the beam ByTube Star fiber laser that fully automates the entire tube cutting process from the loading of
path – right into the center of the melt pool. This allows the deposition full-length tubes to the unloading of finished parts will be on display. Other highlights will include
process to have total directional independence. The machine’s easily demonstrations of nitro-generation equipment and gas mixing of nitrogen and oxygen (MixGas),
accessible, protective cover glass extends the life of internal optics. Primary which provides for faster cutting speeds and efficient gas utilization. A New Solutions hub area will
applications include additive manufacturing, cladding and HLAW. feature stations for software, automation, services, laser packages and consulting.

Laser Mechanisms Inc. Bystronic Inc.

Booth No. W3029 Booth No. S22035

Heavy-plate fabrication Plasma cutting

Soitaab will showcase the Omniatech solution Hypertherm Associates will feature the new
for heavy-plate fabrication. Seamlessly Powermax45 Sync portable plasma cutter. Rae Ripple
integrating fabrication processes into a single will live-cut her latest art piece, a ‘72 Mach 1 Mustang,
unified system, Omniatech provides the with the new Powermax45 Sync. Visitors can try the
ability to plasma cut straight or bevel cuts, new cutter at a hand-cutting station as well. Another
oxyfuel cut, drill, thread, surface and hole highlight will be the XPR460 mechanized plasma
mill, countersink and perform marking in a cutter for mild steel, stainless steel and aluminum.
single machine. Omniatech meets the highest Visitors can learn how XPR with X-Definition technology
industry standards for quality, precision, productivity, reliability and ease of use. It is an operator- improves cut quality, increases cutting speed and
friendly, multi-process all-in-one fabrication system. delivers part-to-part consistency over consumable life.

Soitaab Hypertherm Associates

Booth No. S15073 Booth Nos. S13059 and W3129

October 2024 81
 Press Brakes & Forming Equipment
Laser cutting
MC Machinery Systems Inc. will focus Press brakes
on fabricators challenged by production AMADA AMERICA INC. will present the North American debut of the
bottlenecks and worker shortages. The new EGB 4010e electric press brake. Another highlight will be the
company will showcase equipment and HRB 1003 ATC press brake with automatic tool changer. For the HRB
technology that can eliminate the bane Series, bend indicator sensors ensure accurate bend angles without
of metalworking companies of all sizes – the need for test bends and the crowning system provides consistent angle accuracy across
production bottlenecks that occur in the the entire bend length. Also on display will be the EGB 6020 ATCe, AMADA’s latest generation of
blank-to-bend process. The new technology addresses this proliferation of material handling and servo-controlled press brake. Finally, the EGB 6013 ARce automated bending system that delivers
bending congestion. Products that will be shown and revealed will include laser, press brake and processing of high-mix, low-volume parts will be shown. This machine is equipped with removable
automation technologies that can solve those challenges. part trays, both vertical and horizontal, to enhance productivity and organization.

MC Machinery Systems Inc. AMADA AMERICA INC.

Booth No. S17034 Booth No. S22003

Laser consumables Bending cell

Richardson Electronics will showcase its new line of TRUMPF Inc. will feature its Flex Cell, a new automation
push-fit nozzles for use in Bystronic fiber lasers, which solution that offers efficient bending in combination
includes the classic style made of high-quality copper with the TruBend 7050 press brake. In a few simple
and the precision style made of brass. The new nozzles steps, operators can dock the mobile robot cell onto
can be used in Bystronic machines with automatic the bending machine and operate it automatically. The
nozzle changers. Other highlights will include protective machine can run autonomously for several hours. This
windows and fiber laser lenses for use in lasers of up automation solution helps companies handle order
to 24 kW for several brands; a new series of bellows surges and combat labor shortages. The combined footprint of the Flex Cell and the TruBend 7050
with laminated covers for use in Bystronic fiber laser is under 107 sq. ft. The Flex Cell has a double-sized material buffer that ensures it has enough
machines; and several new dust collection filters. material to feed the TruBend 7050 throughout a night shift.

Richardson Electronics TRUMPF Inc.

Booth No. S16009 Booth No. S18003

October 2024 82
Tube bending Electric plate rolls
BLM GROUP will feature the Elect102, E-Turn and Davi will highlight its e-Power fully electric plate rolls.
Smart all-electric tube bending machines, which With no hydraulic control unit and fewer components,
are all capable of bending in right- and left-hand the compact design integrates easily into a variety of
directions and equipped with VGPNext 3-D graphics production settings and minimizes disruption with
programming software. The robust structure of the fast, efficient installation. The system uses no hydraulic
Elect102 ensures precision and repeatability and the components. This adaptation of electric power to
state-of-the-art electric technology delivers exceptional energy efficiency and eliminates the need all phases of rolling machine operation improves ease of maintenance and energy efficiency,
for hydraulic oils. The E-Turn is capable of handling highly complex geometrical parts in a single while making for a more quiet, compact machine that ensures hassle-free installation. Dedicated
bending cycle. The Smart machine is fast and efficient with optimized axis interpolation, enabling it inverters and actuators at nine independent axis points allow each to operate independently or
to handle even the most intricate geometries within a single work cycle. simultaneously. The rolls provide improved positioning accuracy compared to hydraulic machines.

BLM GROUP Davi

Booth No. S22061 Booth No. S20151

Press brakes Ironworkers & bending

Cincinnati Inc. will highlight its latest laser cutting, Trilogy Machinery will welcome visitors to learn about the
welding and press brake technology along with latest innovations in metalworking machinery and enjoy
related automation. The XForm press brake features live demonstrations of a full range of equipment, including
innovative advancements including faster ram ironworkers, bending rolls and processing lines. One of the
speeds, quieter drive system, larger control screen, featured products is the Sunrise K-Series ironworker, which
larger standard stroke and throat, and standard includes the following at no additional charge: a 40-in. electric
5-axis backgauge. The EZ Bend cell uses cobot backstop for use with all shearing stations; a single opening
technology to simplify programming. Because it die block for punching up to 1.5-in.-dia. holes; gauge tables for
is not tied to any one press brake, operators can roll the EZ Bend to other press brakes and use it punching and notching stations; an LED magnetic work light; and a
where needed. For welding, the EZ Weld leverages a cobot inside of a closed welding cell. set of 11 standard round punches and dies from 3/8 in. to 1.5 in.

Cincinnati Inc. Trilogy Machinery

Booth No. S13085 Booth No. S18151

October 2024 83
Press brakes Panel bender & press brake
Bystronic Inc. will present its latest innovations Prima Power will show the BCe Smart 2220 panel
for sheet metal cutting, bending, automation and bender and eP 1030 servo-electric press brake. The
software. The ByBend Star 120 press brake in a panel bender offers processing of materials up to
new automated mid-size bending cell, the ByCell 4 mm with high accuracy and repeatability enhanced by
Bend Star M, will be shown. Other highlights will dynamic adjustment of the bending angle technology.
include the Xpert Pro 150 press brake featuring a Ergonomics, safety and smart features are all at the
laser angle measuring device, and the new ByBend operator’s disposal. Safety scanners that monitor the loading and unloading area ensure safe
Star 80 compact, high-speed press brake. A New operation. The press brake is for a range of needs, mastering servo-electric technology for high
Solutions Hub area will feature stations for software, accuracy and productivity, hydraulic/hybrid technology for high tonnage and customized solutions.
automation, services, laser packages and consulting. The brake features easy integration into a robotic cell and a full production line.

Bystronic Inc. Prima Power

Booth No. S22035 Booth No. S22107

Press brake tooling

Press brake clamping system
Wila USA will highlight its Tooling Identification
Wilson Tool will feature the eClamp electric clamping
and Positioning System (TIPS), an advanced, fully-
system specifically for press brakes. It uses standard
integrated system designed to optimize press
power and is modular by design for versatility and for
brake operations by automating the identification
simplicity. The integrated LED lighting built into the
and positioning of tools. The solution leverages
body of the punch holder shines light on the working
intelligent sensor technology to streamline the setup
surface, not the front of the press brake. Prominent
process, significantly reducing time and minimizing
clamping indication lights give a clear visual of the tooling that is clamped and ready to bend.
errors associated with manual tool handling. One
Clamping the entire beam with a simple push of the button streamlines the operational process.
of the standout features of TIPS is its ability to automatically identify tools. Each piece of tooling is
Punches and dies lock mechanically rather than with an expanded urethane tube.
equipped with a unique identification marker that the TIPS sensors can instantly recognize.

Wila USA Wilson Tool

Booth No. S27035 Booth No. S27071

October 2024 84
Presses
Electric press
Hydraulic press solutions Beckwood Press will showcase the EVOx electric press that combines

Greenerd Press & Machine Co. will highlight extensive hydraulic press and the flexibility of hydraulic presses with the performance of servo

automation capabilities. Application experts and design engineers will be mechanicals. This press technology uses electricity to create force

available to discuss specific user applications and press requirements. rather than hydraulic or mechanical flywheel systems. The custom

One example that Greenerd will discuss is a 2,500-ton hot-forming press. EVOx model on display will feature 50 tons of force rated anywhere

It is designed, engineered and turnkey-installed featuring 10-ft. square in the stroke via an all-electric actuation system with two linear servo

heated platens maintaining 500-degree F surfaces to ±5 degrees. The actuators and a 30-in.-by-48-in. forming area. The technology requires

press comprises a seven-press order. The 2,500-ton press features an no crankshaft, counterbalance, flywheel, centralized lubrication

innovative mold transfer system that improves the ergonomic and safety or hydraulic power unit and results in no scheduled maintenance

dynamics for operators and reduces the press idle time between cycles. throughout millions of cycles.

Greenerd Press & Machine Co. Beckwood Press

Booth No. S30059 Booth No. S28049

Presses & control systems

Gap frame presses
Aida-America will demonstrate advanced servo press technology,
Stamtec will showcase an iS1-110 servo drive gap frame
including a 200-ton straight-side servo press as part of a full
press and OCP-110 standard mechanical gap frame
progressive die production line stamping parts. The 2-point, direct-
press. The presses will be running under power, with
drive DSF-N2-AB servo press includes the Allen-Bradley servo
demonstrations of the possible stroke profiles in the
control system with multiple features. The press includes an Aida-
servo press as well as the standard mechanical press with
designed and -built, low-speed, high-torque servo motor specifically
powerful Omnilink press controls. A servo coil handling and
manufactured for stamping press applications. It combines the
feeding system will also be on display.
rigidity of a unitized frame with the flexibility of the freely programmable servo motion. Also
featured will be the single-point, direct-drive DSF-C1-A gap frame servo press, which will be
blanking parts with the company’s optimized silent blanking stroke motion profile.

Aida-America Stamtec
Booth No. S28003 Booth No. S28035

October 2024 85
Press automation controller Servo gap frame press
Wintriss Controls Group LLC will demonstrate a new advanced Seyi America will present the SDN1 servo gap frame press,
interface in its SmartPac Pro press automation controller. The latest its latest innovation in servo gap frame technology. It is
functionality in SmartPac Pro and ShopFloorConnect (SFC) gives equipped with a new-generation servo motor, providing the
fabricators and metalformers efficient and easy-to-use tools to control, power and precision to handle various stamping operations.
automate and track their vital operations. Wintriss will introduce the The energy-efficient design keeps operational costs lower
new SmartView Pro Network Interface for the SmartPac Pro. The than those of a traditional gap frame press. The new press
interface allows any PC or mobile device on a network to access and is a testament to the company’s dedication to providing
download information from networked SmartPac Pro controls. Wintriss will also demonstrate its customers with the tools they need to achieve superior
new, compact SFC ShopFloor Tracker hardware device, an economical way for its SFC software to performance and productivity. The SDN1 is available for
automatically collect production data from virtually any machine. order in five options, ranging from 88 to 275 tons.

Wintriss Controls Group LLC Seyi America

Booth No. S29074 Booth No. S28025

Presses
Conventional feed line
Sangiacomo Presses will present information and
Dallas Industries will feature a conventional feed line and its
materials highlighting the features and benefits of its
new interactive and advanced graphical display control for
presses. This includes brochures with detailed materials
press feed lines. In a shared booth with Aida-America, Dallas
that discuss the advantage of the adjustable stroke
Industries will have a live demonstration of a conventional
mechanical press, the benefits of using the shortest
feed line running material on an Aida servo press. A large
stroke for a stamping process and an inside look at what
graphical display with simple-to-operate features will also
goes into creating a world-class stamping press. There
be demonstrated. The 15-in. graphical display is designed to
will also be a representative from Sangiacomo Italy
maximize productivity during start up and into production by providing an HMI touch and diagnostic
present in the booth available to discuss the exciting innovations coming to current and future
screen for the entire feed line process. The graphical display PLC control will also be showcased.
stamping presses and to answer any questions about the company.

Sangiacomo Presses Dallas Industries

Booth No. S33035 Booth No. S28003

October 2024 86
 Sawing
Press feed line
Formtek-Maine will display one of its 24-in.-wide CWP-brand Bandsaws
CoilPak press feed lines, comprised of a ServoMax feed, a Cosen Saws will showcase seven saw models, each of which are designed to
threading table and the model CRS combination stock reel and enhance productivity, accuracy and safety, and new advancements in sawing
straightener. The ServoMax feed is equipped with 460/3/60 automation integration. The NC-510MG and C-300MNC are automatic,
voltage, automatic central lubrication and an adjustable height scissor-style mitering bandsaws with capacities of 3 in. by 20 in. and 9 in. by
cabinet. The threading table supports the material strip across 11.5 in., respectively. The AV-2026NC is an automatic, vertical tilt-frame bandsaw with a 20-in.-by-26.3-
the looping area for ease in thread-up of the line. The C Series straightener is equipped with dial in. capacity. The SH-1000F is a semi-automatic, dual-column bandsaw with a 20.5-in.-by-40-in. capacity.
indicators, automatic central lubrication and a 75-fpm modulating drive with laser loop control The SH-500M is a semi-automatic, scissor-style mitering bandsaw with a 11-in.-by-19.7-in. capacity.
sensor for smooth payout on demand. The stock reel includes hydraulic-powered mandrel The SC-350 is a semi-automatic, circular cold saw with a capacity of 2.362 in. for solids and 4.331 in. for
expansion, a pneumatic actuated hold-down arm and maximum coil OD capacity of 72 in. tubing. The G320 is an automatic, dual-column bandsaw with a 12.8-in.-by-15-in. capacity.

Formtek-Maine Cosen Saws

Booth No. S29059 Booth No. S15011

Presses Sawing & ironworkers

Simpac America will feature DE and DTE Series presses. Scotchman Industries will bring a complete
The mechanical drive of the presses is ideal for flat and range of general to heavy-duty metal fabrication
semi-flat parts due to its sinusoidal slide motion curve. The machinery. Live equipment demonstrations will
machines can be installed as a single press in progressive showcase the features, benefits, cut quality and
or transfer mode or as a fully automated press line. The how the right equipment gets more work done
mechanical drive is a good match for cutting, punching, with these machines. On display will be seven
bending and stamping operations. The solid, low-stress cold saws, including saws from the CPO, SUP,
annealed press bodies are FEM-calculated and optimized by “hot-spot analysis” areas subject to SU and GAA lines. Four ironworkers will also be
higher loads. The automatic centralized lubrication system increases productivity and availability. showcased, including a 50-ton hydraulic machine – the 5014-ET ironworker. Visitors can also see
The recirculating oil lubrication system provides clean oil in metered amounts to all bearing points. the PressPro 110W hydraulic press, two pipe notchers and the 3-in. belt grinder.

Simpac America Scotchman Industries

Booth No. S32035 Booths Nos. S27022 and S27023

October 2024 87
Bandsaws & circular saw Bandsaws & storage towers
Behringer Saws will showcase four saws, including Kasto will showcase its highly dynamic Unibloc
the HBE-320/523GA, which is an automatic U, which is an automated material transport
miter bandsaw for precise miter cuts in metal and storage system that is a simple yet efficient
construction, the sectional steel trade and unit made for handling bar stock. Another
mechanical engineering. The HBE-321A and the material handling solution on display will be the
HBE-511A are automatic horizontal bandsaws Kastoecostore tower system, which is made
designed for economical use in industry and for storing sheet metal. The Micut E4.6, a semi-
the steel trade. Finally, the PSU 450M features automatic bandsaw that can process 13-in. rounds
Behringer’s circular saw technology and is considered an “all-rounder,” capable of cutting tubes, and 18-in.-by-13-in. flat material will also be shown. The saw is designed for single-side miter
profiles, solids and angles. angles and is suitable for cuts from 0 to +60 degrees.

Behringer Saws Kasto

Booth No. S26069 Booth No. S15003

Dual-column bandsaw Circular cutoff saw

HE&M Saw will present the WF1827A dual-column wide- In addition to bending and forming equipment, Kaast Machine Tools will
flange bandsaw with a 27-in.-by-18-in. capacity. The saw highlight the DC 350 X cold saw, a semi-automatic double-gear wet-
is good for cutting bundles and structural shapes. The type circular cutoff sawing machine. The powerful motor and double
9.2-degree positive blade cant is designed to facilitate gear transmission system deliver smooth and consistent operation. The
better tooth loading and aid in relieving stresses in wet cutting system minimizes heat generation, prolonging blade life
beams, reducing blade pinching problems and providing and making it good for cutting materials such as steel, aluminum and
faster cut times. Full stroking bi-directional vises, other metals. Semi-automatic functionality facilitates easy loading and
including the bar-feed’s shuttle vise, reduce the chances for bundle straps or crooked material to unloading of workpieces. The machine also incorporates safety features,
become hung up on vises as the material advances through the saw during cutting. The saw now including blade guards and emergency stop buttons. User-friendly controls and adjustable settings
comes standard with HE&M’s Smart Saw control. allow operators to customize cutting parameters for specific requirements.

HE&M Saw Kaast Machine Tools

Booth No. S15023 Booth No. S15129

October 2024 88
Waterjet Welding

Waterjet machines Welding & safety equipment

Omax from Hypertherm will features new dual-carriage waterjet Miller Electric Mfg. LLC will showcase its latest welding and safety
capabilities on the OptiMax 60X waterjet. The dual carriage equipment from Miller, Hobart, Bernard and Tregaskiss. New
adds a cutting head and an independent motorized Z-axis products will include ClearLight 4x lens technology, available in
carriage. The second carriage allows operators to move the all Digital Performance, Digital Elite, Digital Infinity and T94 Series
heads independently, positioning them closer together for helmets. The OptX handheld laser welder nearly eliminates the
part duplication or further apart for single-head usage. Another highlight will be the Omax Order learning curve for beginner operators and raises productivity up to 10 times. The Dynasty 400 and
mobile application that allows operators and maintenance technicians to access the mobile app in a 800 TIG and stick welders are now enhanced with an intuitive LCD interface that puts capabilities at
manufacturing environment and near the Omax machine with no special equipment required. Users operators’ fingertips with straightforward settings and program memory. Hercules features new 1/16-
can reduce ordering time and improve order accuracy with diagrams and drill-in capabilities. Visitors in. FabCor Hercules welding wire, welding waveform and redesigned extended Tregaskiss consumable.
can also learn about Maxiem 1530 with A-Jet and ProtoMax waterjets and Omax dashboards. Lastly, Copilot cobot system offers quality welding with simplified programming.

Omax Miller Electric Mfg. LLC

Booth No. S13059 Booth No. W4342

Waterjet Welding cobot

Flex Machine Tools will have its FlexJet Waterjet FL-0404 on Abicor Binzel will highlight its iBOTone, a collaborative welding robot
display. The machine is equipped with an IGEMS CNC control, designed for precision and flexibility. This user-friendly cobot assists
CAD/CAM software and hardware including an advanced with welding tasks, improving efficiency and reducing fatigue. It is
Tilter 5-axis waterjet cutting head, Snapper camera for perfect for small batches and complex welds. The welding cobot can be
optimal positioning, Rounder kinematic compensation tool programmed and operated easily and quickly, allowing welding work to
and Straighter perpendicular angle tool. Also on display will be the long-bed FlexCNC G-Series GM- be carried out with consistent quality and without downtime, regardless
20-06 vertical machining center, demonstrating heavy-duty, accurate high-speed cutting, milling, of the batch size. This takes time pressure out of production and allows
drilling and tapping of large parts, as well as machining round and square tubes on its 4th axis. A more effective deployment of skilled employees. In addition, shops can
range of balancing, drilling and tapping arm products will also be demonstrated. now accept orders that they would not have been able to before.

Flex Machine Tools Abicor Binzel

Booth No. S22159 Booth No. W3829

October 2024 89
Robotic welding Robotic welding
Yaskawa Motoman will showcase ArcWorld pre-engineered Pemamek will feature the company’s most advanced welding
flexible, turnkey welding workcells. Visitors can also learn about technologies, demonstrating the Pema Skytrack robot
the latest Smart Pendant applications, the UWI common interface welding station. Also being showcased is the company’s
for robot welding and MotoSim for simulating robot cells. Robotic offline programming system, WeldControl 300, which
arc welding can be collaboratively programmed with lead-to-teach has newly released AutoScan and PathPlanner features.
and can also work with a variety of metals and using any brand WeldControl 300 is for heavy robotic welding automation.
of welding equipment and power supplies. Featured arc welding Integrated into all robotic welding solutions, the software
will include the ArcWorld 6000, ArcWorld 200, ArcWorld RS and facilitates offline programming and simulation of robotic welding operations. The software features
ArcWorld HC welding workcells. These workcells are easy to move parametric path creation, as well as copy, mirror and macro creation. The PathPlanner feature
while offering robotic welding. revolutionizes welding path planning by automating the creation of collision-free paths.

Yaskawa Motoman Pemamek

Booth No. W4871 Booth No. W4681

Welding technologies
Cobot welding
ESAB will offer live arc demonstrations of the Warrior Edge
Universal Robots will showcase new welding features from two
500DX/RobustFeed Edge DX welder and its speed, pulse, thin
of its OEM partners, Vectis and Hirebotics. Vectis will show some
and root weld modes that deliver faster travel speeds, reduce
of its latest user-experience and ease-of-use cobot welding
heat input, increase puddle control and decrease spatter.
features, including QuickTeach and AI Path Optimization.
Other highlights will include the ESAB Cobot and an industrial
QuickTeach makes the Vectis system even easier to use by
robot with the new RoboFeed Edge robotic wire feeder, new
allowing the cobot champion to teach points and optimize
Aristo Edge 500R power source, automation gateway, variety of torch options and dress kits for
paths right at the torch. Hirebotics has developed cobot welding features, including Enhanced Stitch
leading robotic systems. The new InduSuite FloCloud system enables industry to track gas process
Welding, offering the ability to stitch weld through complex paths, the reordering of stitch welds and
parameters, analyze gas consumption, and identify gas leaks and over consumption and the
more. The company’s smartphone-based platform Beacon allows users to teach cobots with ease.
WeldCloud suite of software applications helps analyze and document welding productivity.

ESAB Universal Robots

Booth No. W3801 Booth No. W4755

October 2024 90
Grinding & cutting Welding equipment
Norton | Saint-Gobain Abrasives will feature a range of abrasives, Lincoln Electric will display several welding
including RazorStar belts, quick-change and fiber discs featuring products. Cooper welding cobots help improve
innovative engineered-shaped ceramic grain for tough grinding weld productivity, quality and repeatability
applications when performing off-hand and automated grinding. and the Cooper App is available for easy-
Additional highlights will include Vortex Rapid Prep non-woven to-use programming. eCell robotic welding
flap discs, which last longer and produce increased cutting rates systems are engineered to be cost-effective with a small footprint. They are good for job
and smear-free finishes. The patented Vortex agglomerated shop environments, contract manufacturers and first-time automation users due to minimal
aluminum oxide grain technology enables the cutting power of programming requirements. The Power Wave R450 robotic welding platform runs the systems.
a coarser grit while producing a finer finish in one abrasives disc solution. The Quantum3 line of Next, the combination of the Power Wave AC/DC 1000 SD inverter technology with the addition of
grinding and cutting wheels will also be featured. an extension to the welding torch enables the long stick-out process.

Norton | Saint-Gobain Abrasives Lincoln Electric

Booth No. W3301 Booth No. W4300

TIG welding
Laser welding
One highlight of the Fronius USA booth will be the
Laser Mechanisms Inc. will display the FiberWeld DHµ, which is an ultra-
compact Artis 210, which offers a range of TIG welding
compact laser wire direct energy deposition head for processing large-
functions, including high-frequency, spot and stitch
scale industrial parts, aerospace components and tooling. Engineered for
welding; TAC; and TIG pulse. The welder also excels
high duty cycle production applications, the machine features direct-cooled
at stick welding with HotStart and electrode pulse
reflective optics and transmissive optics. Compatible with most hot-wire
welding. This mobile TIG welding machine makes the
systems, the machine allows filler wire to be fed directly into the beam path
best possible use of input voltage. This not only makes it energy-efficient, but also reliable and
– right into the center of the melt pool. This allows the deposition process
productive. The Artis also has a user-friendly operating concept incorporating a simple press-and-
to have total directional independence. In addition, the machine’s easily
turn button and a clear, illuminated function display. Eleven parameters can be selected directly
accessible, protective cover glass extends the life of internal optics. Primary
without a background menu. It is robust, lightweight and functional.
applications include additive manufacturing, cladding and HLAW.

Fronius USA Laser Mechanisms Inc.

Booth No. W4364 Booth No. W3029

October 2024 91
Welding solutions Abrasives
Fanuc America Corp. will show welding and laser Weiler Abrasives will showcase the expanded Tiger
technologies. The diverse range of CRX cobots 2.0 lineup, including the Tiger Ceramic 2.0 and Tiger
will be on display, featuring a variety of materials Inox 2.0 portfolio of cutting, grinding and combination
joining applications while showcasing solutions wheels. These cutting, grinding and combo wheels offer
for low- or high-volume part runs with any size a superior combination of life and cut rate for maximum
part at any reach or payload. Demonstrating the productivity. A new blending disc product lineup will also be featured. The blending discs are
flexibility of cobots, a CRX-10iA/L cobot mounted ideal for a range of blending, weld cleaning and polishing needs in demanding industries such as
on a 7th axis rail will simulate welding at one station while an operator loads the second station. shipbuilding, structural fabrication and welding. Specialists will also be scheduling consultations
The M-950iA/500 heavyweight robot features a wider range of motion, offering a 500-kg payload at the booth to help visitors understand their abrasive spend, along with ways to increase
capacity and 2,830-mm reach, will be showcased in a new friction stir welding demonstration. productivity and eliminate grinding and finishing bottlenecks.

Fanuc America Corp. Weiler Abrasives

Booth No. W4817 Booth No. W3161

Welding equipment
Welding automation
Wire Wizard Welding Products will feature a variety of
Cloos will show the ExperT Modular System, which is a versatile,
products, including wire delivery products such as conduit,
scalable solution for welding automation, and the CS-3, which
connectors and wire guide modules. Other highlights will be
is a 7-axis, overhead-mounted welding robot with integrated
PowerBall Torch high-performance MIG welding guns and
headstock/tailstock positioners and an indexing transporter. It is
consumables; Torch Wizard robotic torch cleaning stations
perfect for large-scale robotic welding and offers enhanced torch
and accessories; Blue Magic and Blue Chill anti-spatters
accessibility and a compact, all-in-one design. Also being shown, the ArcBoT cobot welding system
and dispensing equipment; Wire Pilot Weld wire feed assist
is a ready-to-weld unit with smart programming software – no robot programming needed. Lastly,
products; WizardGear Robot cable management products;
MIG/MAG and TIG systems, ranging from 400 A to 600 A, deliver production-grade performance
and Weld Central welding optimization technology, including
for automation and manual applications, and the SC-1 robotic welding system features a compact
software, sensors and monitoring systems.
indexing turntable and modular weld tabletops for efficient two-station operation.

Wire Wizard Welding Products Cloos

Booth No. W3453 Booth No. W4829

October 2024 92
 Welders
Forney Industries will highlight its recently introduced
Forney 190 AC/DC-MP and 250 MP Pro multi-process
welding solutions. The 190 AC/DC multi-process welder
features Truset MIG welding technology for easy setup,
AC TIG for aluminum and pulse TIG for precision on thin
materials. With high-frequency TIG arc start and spool
gun capability, it is built to handle various tasks. Dual-voltage (120-V/240-V) input power and 190
amps lets the user weld up to 3/8 in., making it good for professionals. The Pro 250 multi-process
welder also features Truset MIG and a large LCD screen. This welder can handle MIG, flux-cored,
stick and DC TIG welding while being capable of welding up to ½ in.

Forney Industries
Booth No. W3465

Welding tractor
Bug-O Systems will show the Versa-Bug – its first digital
bug. It combines digital smart motors with common
Weld cleaning & abrasives power and communication cables via Ethercat with a
Walter Surface Technologies will highlight its next generation of Surfox weld cleaning systems. The PLC for precise digital control and reliable operation. It
fleet includes two upgraded fieldwork units with the Surfox Turbo and Mini and two upgraded incorporates a linear weaver and height slide for 3-axis
units for heavy-duty shop use with the Surfox 206 and 306. Also being introduced, the Surfox Max motion control and can run on rigid rail, semi-flex rail
combines the portability of the fieldwork units and the cleaning power of the heavy-duty Surfox 306 or PSR rail by changing the carriage. The tractor design can carry up to 100 lbs. at up to 90 ipm
for versatile, heavy-duty weld cleaning in fieldwork applications. Three exclusive new technologies in all positions, with steering and weaving distance only limited to arm length. The Versa-Bug
that further maximize the life of Walter’s high-performance ceramic abrasives – Smart Resin, can be equipped with an onboard Bug-O wire feeder or utilize a Lincoln 4R220 wire feeder and
V-Stong Backing and Max Life Glue – will also be shown. comes standard with automatic height control for CV modes.

Walter Surface Technologies Bug-O Systems

Booth No. W3660 Booth No. W4101

October 2024 93
JOB LISTINGS

The future is being built by the

manufacturing industry

Production Planner Electronics Technician

Juniper Industries, Inc. Yaskawa Motoman Robotics

72-15 Metropolitan Ave. Middle Buffalo Grove, IL 60089, USA

Village, NY 11379

Full time Full time

Responsible for the performance of a variety Yaskawa America Inc. is a global leader in
of duties related to manufacturing, sales, and variable speed drives, motion controls and
inventory to support the operational needs robotics. We look to hire people who value a
of the company; heavy user of the company positive work environment, have a passion for
ERP system Macola; strong emphasis on technology and have a desire to learn and grow.
being detail oriented and well organized. Yaskawa’s culture of continuous improvement
values hiring individuals that are looking for the
Responsibilities Summary: opportunity to stretch their current talents and
» Create and release daily/weekly/ skills to the next level and beyond.
monthly production schedules and
work orders while considering internal The Electrical Technician is responsible for
processing times, available capacity and analyzing, troubleshooting, and repairing
manufacturing release quantities complex technical problems on a broad product
line of PC Board, AC Servo Motor, Inverters, and
[Link] considers manufacturing the most
» Review sales orders and evaluate for AC Servo Drives to the component level using
possible constraints... advanced technical skills. dynamic and exciting industry to work in today.
With cutting-edge equipment – lasers, robots, 3-D
View More View More printers, AI software and more – manufacturers are
producing new and innovative products that are
changing the world for the better.

Learn more today

Create your job seeker profile today Sign up

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