2025 Buyer’s Guide: Welding Product Releases
Thinking about adding a new cobot or welding systems and technology to your shop? Looking for long-lasting consumables? Read on to learn about new, easy-to-use products that enable you to work smarter. The post 2025 Buyer’s Guide: Welding Product Releases appeared first on Fabricating & Metalworking.
New Multi-process Welding Solutions
Forney® Industries Inc. (Fort Collins, CO) offers two new welding solutions: the Forney 250 MP PRO and the Forney 190 AC/DC-MP. The 250 MP PRO is a robust multi-process welder engineered to handle a wide range of welding applications, offering MIG, Stick, and TIG welding processes. Its dual voltage input capability of 120 VAC and 240 VAC makes it versatile, providing unparalleled convenience and flexibility
in various working environments. One of the key features of the Forney 250 MP PRO is its compatibility with generators,
requiring 4,000W continuous output at 120V or 10,500W at 240V, with a maximum of 5% Total Harmonic Distortion (THD). The 250 MP PRO comes equipped with several innovative features designed to make welding easier and more efficient, regardless of experience level.
The 190 AC/DC-MP is built to handle a range of welding tasks with ease, offering AC/DC TIG as well as MIG and Stick welding processes. This flexibility allows users to work on a variety of metals, including aluminum, steel, and stainless steel, making it an essential addition to any metalworker’s arsenal. With dual voltage input options of 120 VAC and 240 VAC, the 190 AC/DC-MP can be powered by standard household outlets or higher voltage sources. It comes equipped with TruSet
, an innovative feature designed to make welding easier and more efficient, regardless of experience level.
Dual-axis Cobot Welding Incorporates UR’s MotionPlus
Vectis Automation LLC (Loveland, CO) is one of the first Universal Robots partners to leverage MotionPlus and demonstrated its Revo Dual Axis system at FABTECH 2024 in Orlando, Fla. MotionPlus enables users to incorporate dual-axis cobot welding with coordinated motion through the controller.
The new multi-axis positioning method can tackle more complex multi-faceted parts and excel in situations where the fabricator needs to get parts in position relative to gravity. The fully coordinated motion system enables shops to achieve precise welding because the cobot doesn’t have to stop welding parts because it and positioner are working in sync. What’s more, operators don’t have to manually move parts.
New Easy-to-use Integrated Mig Welder
ESAB Welding & Cutting Products (North Bethesda, MD) offers the Rustler EM 280 PRO, its next generation inverter-based MIG welder to improve productivity, boost quality and simplify training in industrial fabrication applications. It has a maximum welding output of 280 amps and rated output of 200 amps at 60% duty cycle. It connects to 208V/230V single-phase primary power ± 15% and features Power Factor Correction to lower primary power draw. The Rustler can provide its full output range on a 30A breaker, where older-generation technology required 50A service. It offers an energy efficiency of 82% to lower utility bills. After two minutes of idle time, it enters an energy saver mode to further reduce power consumption.
The Rustler EM 280 PRO comes ready to weld most common base materials with factory-optimized arc programs for carbon steel, stainless steel, aluminum, silicon bronze and flux cored wires from 0.023”- to-0.045”. It has the power to deliver the productivity benefits of spray transfer welding with 0.045” solid and flux cored wires and 0.047” aluminum wires. It can weld up to ½” steel and 3/8” aluminum in a single pass.
Rustler’s 4-wheel drive wire feed mechanism combines high precision, power and reliability to deliver better arc starts and stops without backlash or play in the gears. Large 1.5”-diameter drive rolls provide more wire contact to provide better push force without deforming soft cored and aluminum wires, a common source of feeding problems.
Rustler accepts 8”- and 12”- diameter wire spools. It features 14-segment digital displays on the front panel and offers control functions such as gas pre- and post-flow, run-in speed control, wire burnback control, crater fill, 2T/4T trigger control and Arc Dynamics (a control to fine tune arc characteristics for a crisp/stiff arc when welding carbon steel or a smooth/soft arc when welding stainless steel).
Innovative Technology Eliminates Angle Grinders
LISSMAC Corp.’s (Mechanicville, NY) EBSC is specifically designed to streamline and enhance surface processing. The EBSC is a groundbreaking alternative to traditional angle grinders by utilizing a contact roller system that ensures precise, straight lines, while also extending the lifespan of consumables. This innovative design reduces tool handling errors, leading to less wear and tear on equipment and operators alike.
The ESBC can process both tri-dimensional and flat parts, allowing for applications across various industries. The adjustable belt speed drive, combined with a return pulley and additional stabilization pulley, ensures consistent processing results. Plus, the machine’s flexible belt can twist to accommodate tri-dimensional parts, further enhancing its adaptability. Additionally, the machine’s adjustable pneumatic belt tension allows operators to customize the tension based on the task at hand. Stronger tension settings are ideal for tasks such as weld seam removal, while lighter settings are perfect for processing contoured parts. The EBSC’s belt system features a self-centering function that eliminates the need for manual adjustments, making it more efficient and operator friendly. It is well-suited for industries where the ability to efficiently process tri-dimensional parts and remove weld seams without relying on an angle grinder is crucial.
Abrasives Offer Unprecedented Grinding Performance
Fiber Discs, Quick-Change Discs and Belts are offered in 36-grit.Saint-Gobain Abrasives (Worcester, MA), one of the world’s largest abrasives manufacturers, offers Norton RazorStar Fiber Discs, Quick-Change Discs and Belts featuring innovative engineered shaped ceramic grain, a breakthrough technology with unbeatable performance even in the toughest grinding applications. A unique combination of razor-sharp grains with a supersized grinding aid helps to significantly reduce heat generation for cooler cuts and longer life on a range of materials such as carbon steel, aluminum, stainless steel, nickel alloys and other hard-to-grind metals.
Enabling exceptionally high cut rates and material removal, the engineered shaped grain in RazorStar products feature a consistent shape from grain-to-grain along with razor-sharp cutting points. For long, unparalleled abrasives life, the unique patented geometry and tough micro-structure enable the grain to stay sharp, as new cutting points are exposed when the grain fractures. RazorStar abrasive products also feature a high concentration of grains that are oriented in an upright position, so the abrasives are ready to cut and aggressively perform at their sharpest point. “We are seeing an up to 50% cutting performance improvement compared with other ceramic discs on the market today, and we are very excited to offer our customers abrasive discs that will take their grinding performance to a new level of efficiency when removing welds, grinding, beveling and doing deburring,” said Jeremy Spencer, product manager, Norton | Saint-Gobain Abrasives.
Vision 3D Software for Flat Panel Welding Applications Solutions
Few welding automation suppliers know shipbuilding as well as Pemamek Ltd. (Cincinnati, OH), a leader in automated welding systems used by the largest shipbuilders in the world. Pemamek has developed the PEMA Vision 3D software specifically for flat panel welding applications prevalent in shipbuilding. Signaling a big leap in flat panel welding automation, Vision 3D software solves multiple challenges faced by shipbuilders including inconsistent workpiece dimensions, weld quality and skilled labor shortages.
Vision 3D’s modeling function, featuring customized defaults for faster weld path development, creates accurate 3D models using data gathered by weld piece scans. Welding schedules are met with little or no delay, keeping the shipbuilding operation moving efficiently. An intuitive, easy-to-use interface enables team members at any skill level to learn the software, an especially valuable feature that enables manufacturers to meet the challenges faced when there is a lack of skilled workers on-site. Additionally, shipbuilding sites can be hazardous workplaces with personnel performing welds within closed or close-knit spaces with harmful fumes resulting from weld piece materials. A Pema automated welding solution equipped with the Vision 3D software allows the welder to move out of these spaces and into the operator’s seat for a healthier work environment.
Pema Vision 3D seamlessly connects with PEMA Vision Robot Welding Portal (VRWP) for shipyards, a compact system developed for micropanel and sub-assembly welding. The VRWP series comes equipped with PEMA’s WeldControl 200 software and is fully compatible with the Vision 3D software.
On-site Nitrogen Generator is Industry’s Most Efficient Solution
South-Tek Systems LLC (Wilmington, NC) offers the new N2GEN-FLEX Nitrogen Generator — a groundbreaking new system designed to transform the way businesses generate and utilize nitrogen on-site. With its industry-leading air-to-nitrogen ratios and unparalleled efficiency, the N2GEN-FLEX delivers significant savings in energy costs, service costs, and overall operational efficiency.
The N2GEN-FLEX uses Pressure Swing Absorption (PSA) technology to deliver the most efficient air-to-nitrogen ratio in the industry, which is significantly more efficient than competing systems. This advanced technology reduces energy consumption by 20% or more when compared to traditional nitrogen generators, ensuring lower operational costs and a longer lifespan for the system’s components. The N2GEN-FLEX is engineered to provide superior performance for operations requiring nitrogen from 95% to 99.999% purity and flow rates from 400 to more than 2.200 SCFH. The N2GEN-FLEX is the ideal solution for industries where high-purity nitrogen is critical, including:
- Food & Beverage
- Pharmaceuticals
- General Manufacturing (e.g., automotive, metal fabrication)
- Chemical & Petrochemical Processing
With energy savings of 20% or more, the N2GEN-FLEX is an investment that pays for itself quickly while providing continuous, on-demand nitrogen supply. “This new product is not just about being in control of your nitrogen — it’s about delivering efficiency, reliability, and flexibility,” said Mike Dolan, director of sales and marketing, South-Tek Systems. “The N2GEN-FLEX sets a new standard for nitrogen generation, empowering organizations to take control of their nitrogen supply and realize substantial operational savings.”
Fast, Efficient Metal Removal on Flat and Curved Surfaces
WALTER Surface Technologies (Windsor, CT) has introduced FLEXCUT XX, a new ceramic grinding wheel, designed for ultra-fast material removal on steel, stainless steel and mill scale. FLEXCUT XX is engineered for superior performance on flat and curved surfaces, combining a self-sharpening ceramic grain blend with exclusive SMART RESIN Technology, a feature which exposes fresh grains at the optimal time to achieve the most productive balance between sharpness and life. Its open diamond cut pattern ensures smooth, clog-free grinding ensuring consistent disc performance throughout its entire lifespan.
Available in 4-½” to 7” diameters, FLEXCUT XX’s Type 29 shape maximizes surface contact for precision grinding with fewer passes and no risk of contamination—making it the ideal solution for a wide range of applications.
Strip Discs Deliver Superior Cleaning Power and Extended Product Life
Weiler Abrasives (Cresco, PA), a leading producer of abrasives and power brushes for surface conditioning, announces a new lineup of non-woven cleaning and stripping products designed to remove coatings and rust in preparation for welding and manufacturing operations. New Tiger Ceramic and Tiger Silicon Carbide (SiC) non-woven strip discs deliver superior cleaning power and extended product life for applications in metal fabrication, shipbuilding, automotive and other industries.
Tiger Ceramic strip discs clean up to 20% more material and are up to 20% faster than a leading competitive product, delivering superior cleaning power and extended product life for steel and stainless steel. The self-sharpening ceramic grains effortlessly clean welds and remove thick coatings and stubborn rust, maintaining a consistent cut rate for greater efficiency. The ultra-flexible non-woven nylon fiber and resin formula create a wider footprint and increases the contact area with the work surface, boosting productivity without compromising disc life. The ceramic strip discs are ideal for weld cleaning, surface preparation and blending, as well as removing thick coatings and heavy rust.
The Tiger SiC strip discs clean up to 30% more material than the industry leader in this category. These discs offer a fast-cleaning, long-life solution for steel and stainless steel. Silicon carbide grains provide a high initial cut and penetration, making them ideal for cleaning hard surfaces such as hard-grade steel, structural steel, hot-rolled steel and stainless steel. The ultra-flexible non-woven nylon fiber and resin formula creates a wider footprint and increases the contact area with the work surface, boosting productivity without compromising disc life. The discs are low sparking, which is necessary for confined spaces and areas where hot work is not permitted. Tiger SiC strips are ideal for removing paint, rust, light mill scale and varnish as well as for weld cleaning.
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