FLATLINE | Gantry FSW Series

FLATLINE | GANTRY FSW SERIES

All-access availability for non-stop production
Dedicated in elevating performance standards and fully process reliability, Stirtec machines within the G-series are designated to achieve highest welding speeds on application within the automotive and other industries. The gantry system combines robust and stiff machine design with fast acceleration travel speeds, reducing production costs to a minimum. The manufacturing of large full-EV battery trays and floor panel systems require short FSW welding and part handling times to fulfill the desired quantities. With welding speeds up to 5000mm/min, Stirtec gantry systems are employed by leading OEMs (Original Equipment Manufacturers) and their suppliers for high-volume production in the automotive industry. The special developed FSW spindle system executed the welding process force controlled. Including the inline process monitoring software STIRlytics®, process forces and real-life data collecting are combined into a quality report, which ensures fully traceability throughout the FSW welding process. Seamlessly integrated into the desired automation system, Stirtec machines within the G-series are setting new milestones in serial production. 
FSW force control system 
STIRlytics process monitoring software for data monitoring
Simultaneous part handling to the welding cycle
Achievement of FSW welding speeds up to 5000mm/min

Overview of the gantry FSW series

G-FSWC2318

G-FSWC2318
  • Application for welding: large battery tray for full EV and PHEV vehicle components
  • FSW machinery with exceptional rigidity for part loading from front, back and top side of the machine
Download DatasheetG-FSWC2318
The Stirtec G-FSWC2318 provides state-of the art Friction Stir Welding technology with seamlessly merging power and precision in a single, versatile production unit. The robust and stiff machine design allows the achievement of highest welding speeds under following the welding path with stabile accuracy. Applications can be fully-loaded from front for welding and transferred outside of the machinery due to rear side opening. With the extension of the tool magazine up to 120 sockets, the G-FSWC2318 is the perfect solution on ever-changing requirements demanding individual and flexible production. The machine is predominately used for automated production, demands for manual loading and unloading are also given by the full enclosure machine system.

Machine characteristics of Stirtec G-FSWC2318

  • application size up to L 2000mm x W 1500mm
  • use of Sinumerik 840D sl machine control system
  • STIRlytics process software for 100% traceability
  • FSW force measuring system in X-, Y- and Z-direction
  • highest process stability and accuracy due to rigid machine frame
  • suitable for all aluminum alloys and die casting components
  • automatic tool change system for 50 tool pockets (up to 120 sockets)
  • FSW spindle for welding forces up to 40kN, torque: 5.000rpm
  • Heidenhain absolute scales leads to direct machine feedback
  • achievement on highest FSW welding speeds (up to 5.000mm/min)
  • upgradable milling functionality in a single machining center
  • full protection and CE-conformity​
For more information, please get in contact

FLATLINE FSWC-2519

FSW2519
  • Application for welding: large battery tray for full EV and PHEV vehicle components
  • Table extension for simultaneous part operation (up to 5.500mm in length)
  • FSW machinery for the achievement of highest welding speeds in reference to the application (up to 5.000mm/min)
Download DatasheetFLATLINE FSWC2519
Download DatasheetG-FSWC2519
The Stirtec Flatline FSWC-2519 is seen as most-productive Friction Stir Welding center following the production of application within the automotive industry for large full-EV battery trays and midsize battery systems. Due to the open gantry design, the accessibility for loading and unloading is perfectly given. In regard to the part dimensions, automatic part handling can be performed simultaneously to the FSW welding cycle without any disruption of the production process. Following the achievement of highest welding speeds up to 5.000mm/min, the cycle timing for welding is reduces to a minimum. The machine type of the Flatline FSWC-2519 synthesizes latest FSW technology RapidStir® with the possibility for multi-spindle installation. 

Machine characteristics of Stirtec Flatline FSWC-2519

  • application size up to L 2200mm x W 1500mm (table extension for dual operation possible)
  • use of Sinumerik One machine control system
  • STIRlytics process software for 100% traceability
  • FSW force measuring system in X-, Y- and Z-direction
  • highest productivity due to open gantry machine design
  • suitable for all aluminum alloys and die casting components
  • automatic tool pick-up station with 5 tool pockets
  • FSW spindle for welding forces up to 25kN, torque: 5.000rpm
  • synthesizing Rapidstir® welding technology
  • achievement on highest FSW welding speeds (up to 5.000mm/min)
  • upgradable multi-spindle with the installation of second gantry system
  • easy accessibility for automatic part handling (loading, unloading)
For more information, please get in contact

Applications for the Flatline Series

E-Mobility

E-Mobility

The cooling circuits of battery trays, stator housings, and inverter housings in electric vehicles are sealed watertight using Stirtec's FSW machines. Stirtec's FSW machines are excellently suited for manufacturing battery trays due to their high welding quality. 
EV / PHEV Battery Trays
Find out more about E-Mobility
Dominik Kaineder

FOR FSW PROTOTYPE PRODUCTION AND MACHINERY
Your contact person: Dominik Kaineder

Are you interested in determining the feasibility of a new concept using Friction Stir Welding? Or do you require assistance in choosing the most-sufficient system for serial production for your application?
Please contact us direct - we'll gladly provide guidance and support.

dominik.kaineder@stirtec.at
+43 676 30 93 922