“The Warrior DualFeed delivers superior welding performance because it features ESAB’s PreciDrive wire drive system -an encoder-based drive system that delivers precision wire feeding with better arc starts and stops, without backlash or play in the gears,” said Jeff Chittim, Senior Product Manager for North America, ESAB.

PreciDrive features four gear-driven drive rolls with a large diameter (1.5 in.) for more gripping area to provide more pushing force without deforming soft, cored and aluminium wires, a common source of feeding problems. The design improves accuracy at lower speeds, has the power to feed larger diameter cored wires and the high speeds necessary for smaller diameter hard wires. The wire feed speed adjusts from 32 to 984 inches per minute.

Common reasons to use dual feeders include using a solid MIG wire for a tack weld or root pass and then switching to a cored wired for fill passes to increase deposition rates or support all-position welding. Dual feeders are also ideal for welding with two different shielding gases, such as one for short circuit MIG and another for spray transfer welding.

Operators can switch from one wire to another using controls on the feeder or from the MIG gun trigger. Parameters such as run-in speed, crater fill and burn-back can be adjusted and saved individually. Digital meters display parameters, and a detachable control box enables adjustment when the feeder is mounted on a boom or mezzanine. MIG gun options include the Tweco Supra XT 450, Tweco Spray Master 450, Tweco Classic 5, Tweco Elite 450 and Tweco SEFC 350 for self-shielded wires.

ESAB builds its Warrior system for extreme reliability in heavy industrial applications, such as a railcars, truck and trailer fabrication, heavy equipment repair, hardfacing, general fabrication and oil and gas for pipe applications. They are available through standard distribution and online sales channels.

About ESAB

ESAB is a world leader in fabrication technology. For more than 100 years ESAB has transformed industries built by fabricators, providing complete workflow solutions through our diverse portfolio of products from more than 40 of the most trusted brands in welding and cutting in the world. From industrial demands to repair and maintenance, innovators that shape the world rely on ESAB’s portfolio.

Advanced Process Control

The UB Series incorporates 40 kHz closed-loop feedback, providing even faster and more accurate control of current or voltage compared with previous models. This high-speed sampling ensures precise energy delivery and stable waveforms, resulting in improved weld consistency, reduced part distortion, and higher process reliability.

An all-new “Weld to Displacement” feature adds another dimension of control, automatically ending the weld once a programmed displacement target is reached—ideal for delicate or variable materials.

Automation-Ready Connectivity

Designed for both benchtop use and integration into a fully automated system, the UB Series features a new integrated 10-inch high-resolution touchscreen or optional remote display for flexible installation in production cells. Modern industrial communication protocols—REST API, MQTT (IoT), EtherNet/IP (optional), RS-232, and Direct I/O—enable seamless integration into Industry 4.0 environments.

Data Handling and Network Security

Full waveform data for current, voltage, power, and resistance is captured at 40 kHz and stored at 16-bit resolution for detailed process monitoring and statistical analysis. Remote access allows engineers to perform diagnostics, software updates, and maintenance securely over the network. To protect connected systems, the UB Series employs certificate-based authentication and TLS encryption via OpenSSL, ensuring high-level data protection in connected manufacturing environments.

About AMADA WELD TECH

Founded in 1946, AMADA is a global leader in metalworking machinery, and AMADA WELD TECH, INC. – established in 1948 – is a proud AMADA Group company dedicated to solving customers’ manufacturing challenges. Recognizing that no single solution fits every application, AMADA WELD TECH combines decades of independent expertise with the strength and innovation of a worldwide organization to provide innovative, reliable manufacturing technology solutions. The company designs and manufactures equipment and systems for resistance welding, laser welding, laser marking, laser cutting, hermetic sealing, and hot bar reflow soldering and bonding, serving markets including medical devices, battery, aerospace, automotive, and electronic components. AMADA WELD TECH is an ISO 9001–certified company.

As electric motor design continues to evolve, manufacturers are turning to pre-formed rectangular copper conductors known as “hairpins,” instead of traditional round-wire windings. These conductors are inserted into the stator core, locked in place, and joined at their ends. AMADA PRESS SYSTEM’s ES-1A 48-axis coil processing machine combines feeding, straightening, peeling, cutting, bending, and pressing flat copper wire in a continuous process.

AMADA PRESS SYSTEM technologies are also making a significant impact in stator manufacturing. The company’s modular three-segment stator stamping approach replaces traditional single-piece stamping, improving material yield, reducing press size, and lowering total energy use. Compact, high-precision presses combined with automated feeders, like the SDEW-i3 GORIKI high-rigidity, high-speed precision series of presses and the ALFAS-03ARZ high-speed, high-precision NC roll feeder, enhance consistency while eliminating the need for large-scale infrastructure.

AMADA WELD TECH offers several technologies for welding the hairpin ends, including laser welding, micro TIG welding, and resistance brazing. Laser welding offers a non-contact method ideal for high-speed assembly and integrates seamlessly with vision systems for alignment and quality assurance. Micro TIG welders provide a flexible, cost-effective alternative for low-volume or maintenance operations, while resistance brazing ensures strong joints well-suited to more forgiving geometries.

AMADA WELD TECH and AMADA PRESS SYSTEM’s integrated technology ecosystem empowers manufacturers to improve quality control, streamline workflows, reduce operational costs, and accelerate the development of next-generation electric motors. This synergy is amplified by AMADA ONE, an initiative that brings together the expertise of AMADA WELD TECH and other AMADA Group companies. By offering unified solutions and innovative resources, AMADA ONE helps customers overcome every metalworking challenge and achieve greater efficiency and process synergy across fabrication, stamping, welding, and machining operations.

About AMADA WELD TECH

Since 1948, AMADA WELD TECH has worked to achieve one goal: to solve customer’s manufacturing challenges. Knowing there is no one solution that fits all, the company strives to provide customers with innovative and reliable manufacturing technology solutions in an effort to be their single source provider. AMADA WELD TECH manufactures equipment and systems for resistance welding, laser welding, laser marking, laser cutting, hermetic sealing and hot bar reflow soldering and bonding. The company serves a wide range of markets including medical devices, battery, aerospace, automotive and electronic components. AMADA WELD TECH is an ISO9001 certified company.

“These four educational events take a deep dive into current welding technology topics for welding professionals and industry experts,” says Jonathan Joseph, Manager, Conferences, AWS. “If you’re interested in advancing your career goals by learning about new industry techniques and standards, as well as networking with a who’s who of industry professionals, you should consider these AWS conferences.”

The marquis events kicked off in February with the Inspection Expo & Conference, Feb. 3-4, 2026, in Austin, Texas. The conference, hosted by AWS and the American Institute of Steel Construction (AISC), is the premier event hosted by inspectors for inspectors, focusing entirely on welding inspection.

“While the IEC is dedicated to the core areas of welding inspection, the conference also highlighted the recent and increasing role of artificial intelligence,” says Bill Newell, Conferences Chair. In addition, a pre-conference event, Upholding Integrity: Legal and Ethical Standards in the Welding Industry, on Feb. 2 was for those who want to learn more about legal and ethical responsibilities of a CWI.

From April 13-15, 2026, the third Shipbuilding and Aluminum Conference takes place in New Orleans. This three-day event brings together industry leaders, engineers, and professionals to explore the latest technologies, materials, and practices shaping shipbuilding and aluminum welding. The conference offers tabletop exhibits, a happy hour, and multiple opportunities to connect with peers, suppliers, and industry innovators.

The Welding Automation Expo and Conference happens June 2-4, 2026, in Minneapolis, Minn. WAEC features industry experts and end users who delve more deeply into automation. Receptions and tours provide additional information and networking opportunities.

Highlighting welding compliance, procedure and qualification, the premier welding event Welding Summit 2026: Improving Welding Competency takes place Aug. 5-7 at The Woodlands Resort, Texas. Keynotes Dwayne Mattox, application engineer at Miller Electric, and Patrick Van Fleet, automation expert at Airgas, will speak to their professional welding experience in the military and beyond.

Miller Electric Mfg. LLC, a leading manufacturer of arc welding equipment, has announced the release of its ArcCapture weld camera systems, designed to enhance training, instruction and efficiency in both educational and automated welding environments.

Compact, portable and easy to install, ArcCapture delivers clear, high-definition (1920 x 1080) views of the welding arc in real time. For schools and training centers, ArcCapture streamlines classroom instruction by allowing instructors to project live demonstrations to an entire class, observe individual welds remotely and guide students without crowding the booth. Every student gets a front-row seat to every weld, while instructors gain the visibility and flexibility to provide next-level training that helps their students succeed.

In manufacturing and automation settings, the ArcCapture weld camera systems seamlessly integrate with robotic and automated welding systems. The cameras mount directly to the torch, table or end-of-arm tooling, enabling operators to view welds in real time for process control, inspection and quality assurance.

With both standard and Wi-Fi enabled models, ArcCapture offers flexible options for any weld environment. The ArcCapture with Wi-Fi provides multidevice streaming for easy connection to phones, tablets and computers, while the standard model requires a hard-wired connection.

About Miller

Miller Electric Mfg. LLC, headquartered in Appleton, Wisconsin, is a leading worldwide manufacturer of Miller brand arc welding products and is a wholly owned subsidiary of Illinois Tool Works Inc. (NYSE: ITW).

“ESAB’s Warrior Edge aluminum system delivers best-in-class arc characteristics, exceptionally smooth wire feeding, reduced arc-striking defects compared to other systems and a durable gun design for harsh environments,” says Jeff Chittim, North America Senior Product Manager, ESAB. “To further optimize quality and throughput, pair this system with AlcoTec® aluminum MIG wires, which exhibit smoother wire feeding, fewer tangles, little to no shavings and excellent arc stability.”

Push-pull MIG systems maintain constant wire tension between two sets of drive rolls: one set in the feeder and one set in the gun. As a result, they solve common feeding problems, such as wire slippage, erratic arc performance, wire burning back to the contact tip, cold lap and bird nesting at the feeder rolls. ESAB’s new aluminum welding system will be available through standard distribution and online sales channels later this year. An air-cooled gun option will be available in early 2026.

Advanced and Operator-Friendly

The Warrior Edge power source with RobustFeed Edge feeder allows ordinary welders to benefit from sophisticated WeldModes, which eliminate the need for continuous training and over reliance on individual operator skill. When using a synergic WeldMode, operators can fine-tune performance simply by adjusting the wire feed speed and trim control knobs and the system will maintain optimized arc characteristics. An Arc Dynamics function, also controlled by a single knob, adjusts the arc for faster travel speed and adds stability control for specific travel speeds, better control of the weld pool, and enhanced bead geometry.

The RobustFeed Edge wire feeder includes ESAB’s TrueFlow digital gas control technology to automatically prevent insufficient gas flow and optimize flow during arc starts and welding, a common source of quality issues and gas waste. TrueFlow can save up to $650 to $1,300 per year, per machine in gas waste in typical use cases.

The Warrior Edge 500 DX has built-in connectivity and comes with a lifetime subscription to the InduSuite WeldCloud Fleet online software application.

About ESAB

ESAB is a world leader in fabrication technology. For more than 100 years ESAB has transformed industries built by fabricators, providing complete workflow solutions through our diverse portfolio of products from more than 40 of the most trusted brands in welding and cutting in the world. From industrial demands to repair and maintenance, innovators that shape the world rely on ESAB’s portfolio.

How does WireSense work?

The measurement is contact-based via a short circuit without welding and works with all common filler materials. The Fronius welding power source—an iWave or TPS/i—detects edges or joints and transmits this information to the robot controller. The controller compares the data with the programmed path and automatically corrects the tool center point (TCP) so that the seam is always welded exactly at the desired location.

What’s new with WireSense?

• Support for all seam geometries: fillet welds, I-joints, flanged seams, and complex machined shapes
• More flexibility – ideal for companies with varying sheet thicknesses and demanding geometries
• Reliable detection even with thicker materials from 4 mm
• Can be used with steel, stainless steel, aluminum, and CrNi alloys

What is required for WireSense?

The prerequisite is CMT-ready equipment consisting of the Robacta Drive CMT drive unit, the appropriate CMT wire buffer, and the WireSense software package – the CMT software itself is not required.

Integration is carried out via the Fronius welding power source, which transmits the sensor signal to the robot controller at lightning speed. Fronius works closely with robot manufacturers to ensure that the most common robots can process WireSense signals optimally.

Free update for new features

The good news for anyone already using Fronius WireSense is that a free software update is all that is needed to use all the new functions. Tip: An update may also be necessary for the robots used – please check with the robot manufacturer.

The combination of robot and scanner makes it possible to supplement the forward motion of the robot with a further, freely programmable movement of the laser in any desired direction. This “oscillating motion” is facilitated through specially developed lightweight mirrors. By enabling scan frequencies in the kilohertz range, this technique increasing the thickness of sheets that can be processed in heat conduction welding from 0.12 to 0.24 inches. The new technology allows users to tailor the parts’ bonding surfaces – which are melted directly by the laser beam – to suit each application. This makes for a more reliable process and results in higher quality parts. The fact that the beam can now also be guided using the scanner also makes it easier to achieve tighter tolerances.

“BrightLine Scan is another example of TRUMPF’s determination to offer industry-relevant solutions by focusing on the needs of sheet metal fabricators,” says TRUMPF product manager Robin Stuhler. “Companies can enjoy big benefits by incorporating this technology in their day-to-day work, because tighter tolerances in the welding process mean less scrap, faster processing and lower costs.”

FABTECH marked the North American launch of the new BrightLine Scan technology for TRUMPF’s TruLaser Weld 5000 laser welding machine.

Dual method of guiding laser beam makes process more robust

The task of guiding the laser beam via the laser scanner in BrightLine Scan is performed by the freely programmable PFO 20 focusing optics. Developed by TRUMPF engineers, these are integrated into the robot’s welding optics. Guiding the beam using a combination of the robot and scanner provides a major boost to the robustness and flexibility of the laser welding process.

“Previously, we had to position the laser beam right over the seam to guarantee a high-quality weld,” says Stuhler. “If you deviated from the right spot by a fraction on an inch, or even less, the part often had to be scrapped. But now that the beam can also be guided via the scanner, it’s easier to achieve tighter tolerances. That makes it possible to correct any minor inaccuracies that might have occurred in during previous steps such as bending.

Simple to program and use

BrightLine Scan is seamlessly integrated into the robot’s welding optics, so programming the TRUMPF welding cell is as quick and easy as ever. TRUMPF provides companies with TechSets, which contain all the parameters they need for common applications. Fabricators can also benefit from BrightLine Scan in the welding cell’s TruTops Weld offline programming system. This allows users to program the machine while it is busy welding a different part.

“Offline programming is a fast and economical solution for low and high-volume production,” says Stuhler, “and the ability to store all the basic process information directly on the machine creates a buffer that is useful for companies facing a skilled worker shortage.”

The new technology provides a reliable solution for welding sheets up to 0.24 inches thick, which makes it particularly suitable for agricultural and construction machinery. The high precision and quality of the seams also makes it an efficient choice for manufacturing furniture products and EV battery trays. BrightLine Scan is also a great option for producing electrical cabinets.

About TRUMPF

TRUMPF is a high-tech company offering manufacturing solutions in the fields of machine tools and laser technology. It drives digital connectivity in manufacturing through consulting, platform products and software. TRUMPF is one of the technology and market leaders in highly versatile machine tools for sheet metal processing and in the field of industrial lasers. In 2023/24, TRUMPF employed 19,018 people and generated sales of 5.2 billion euros. With about 90 companies, the TRUMPF Group is represented in nearly every European country as well as in North America, South America and Asia. The company has production facilities in Germany, France, the United Kingdom, Italy, Austria, Switzerland, Poland, the Czech Republic, the United States, Mexico and China.