Stirtec's Turnkey Systems
With our FSW machines and turnkey systems, you are investing in high performance "Made by Stirtec." Depending on part size and requirements, different system concepts are available – from compact enclosed FSW machines to flexible gantry systems for large-volume components. All systems operate as standard with a powerful Siemens control system, combined with our quality software STIRlytics for inline process monitoring and data analysis, as well as our RapidStir® technology for maximum welding speeds and shortest cycle times.
In addition, we design and manufacture individually tailored clamping devices for each application – our PowerClamp systems, which are engineered and optimized for the respective process ensuring maximum precision and process stability. The overall concept is complemented by our specially developed MaXstir® FSW tool series, which stand for highest precision, exceptional process stability and outstanding tool life. The result is a fully integrated solution where every component is designed for efficiency, quality, and production readiness – ensuring a faster and safer path to series production.
Stirtec machine portfolio
High-Performance meets innovationOur machine portfolio covers the entire spectrum – from compact, space-saving solutions to large-format high-end systems with component capacities of 2100 mm in width and several meters in length. This allows us to serve all key applications in the automotive industry – from safety-critical structural components to parts for power electronics and electric drives as well as large-volume battery carriers for e-mobility. The heart of every welding system is our spindle technology, equipped with a high-resolution force measurement system. Integrated vibrosensors allow even the slightest process deviations to be detected with precision. For maximum process stability and reproducible weld quality, our machines are vibration-optimized from the outset – thanks to targeted use of advanced FEM and modal analyses during the design phase.
With the Flatline machine series we offer an open, modular concept developed specifically for the automotive industry. It can be flexibly adjusted in Z-height and X-length, providing optimal accessibility for simple loading and unloading concepts – ideal for integration into fully automated production lines. We also set standards in efficiency and availability during ongoing operation. Our systems are optimized for low maintenance and easy service: The modular media flow enables short intervention times, while drive components, wear and spare parts can be replaced quickly and easily. Combined with the latest generation of control and drive systems from Siemens, our machines are ideally and reliably designed to meet the requirements of highly automated series production. Furthermore, the systems are deliberately user-friendly: An additional touch panel gives machine operators quick access to process parameters and operating data at any time – for intuitive control, transparent process management, and noticeable efficiency in daily operations. Our machines can be optionally equipped with camera and DMC reader systems for full part traceability and enhanced process monitoring. Combined with an automatic tool change system that significantly reduces setup times, production achieves maximum flexibility and efficiency.
PowerClamp systems
Clamping technology, precisely tailored to your component
Our PowerClamp systems are the key component of every project – because without secure part clamping, a stable FSW process is impossible. Therefore, we place great importance on a well-thought-out overall concept that perfectly considers accessibility, safe absorption of process forces, and controlled heat dissipation. The fixtures are designed, manufactured, assembled, and commissioned entirely in-house by our engineering department. From simple manually operated systems to highly complex, fully automated clamping solutions, we cover the entire spectrum depending on the part requirements and process complexity. We rely on the appropriate clamping technology – pneumatic, hydraulic, or, newly in our portfolio, electrically actuated –ensuring maximum flexibility and efficiency. Special support elements guarantee precise part positioning and reliable fixation in the fixture. Apart from that, inductive sensors or proximity switches are used to precisely detect whether a component has been loaded correctly or which component it is.
Optimized clamping sequences minimize part distortion during friction stir welding without compromising weld quality. Our PowerClamp systems are seamlessly integrated into the machine control, NC/PLC systems, and fully automated production cells. This ensures that interfaces and communication are perfectly aligned, so process parameters, status messages, and safety functions are reliably captured and transmitted at all times.
The result: clamping technology that is perfectly tailored to your components and production processes, delivering maximum process reliability, and seamlessly integrating into your production line.
MaXstir-Tools
Proven for maximum precision and lifetimeIn friction stir welding, often just a hundredth of a millimeter determines success or scrap. That’s exactly where our strength lies: We develop tools that impress in every detail. With over 20 years of experience in friction stir welding tool development, we combine in-depth materials expertise, state-of-the-art metrology, and comprehensive process understanding to create solutions that impress in the long-term performance. For our FSW tools, we exclusively use materials that reliably perform even under the highest mechanical loads and temperatures. Through targeted heat treatments, these materials reach their full potential – setting new standards in durability and performance. Additionally, an intelligent tool design with optimized force application ensures that unwanted stresses and deformations are effectively avoided. To ensure uncompromising quality, each tool is equipped with an individual Data Matrix Code (DMC), providing complete traceability of the material batch, production data, and all measurement and inspection protocols. Furthermore, our FSW tools are qualified in a realistic test environment, ensuring that they not only meet the required specifications but also deliver reproducible performance over their intended service life. Each test series is clearly linked to the tool ID, ensuring full documentation of force and torque curves, stirring behavior, and cycle stability.
The result: tools that represent process stability and, with extended service life, contribute to a noticeable reduction in operating costs.
Anwendungen für Rührreibschweißen (FSW)
Elektromobilität
Energieübertragung
FÜR FSW PROTOTYPENPRODUKTION UND MASCHINEN
Sind Sie daran interessiert, die Machbarkeit eines neuen Konzepts mittels Rührreibschweißen zu ermitteln? Oder benötigen Sie Unterstützung bei der Auswahl des für Ihre Anwendung am besten geeigneten Systems für die Serienproduktion?
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