Steel construction projects increasingly require customized designs, precise manufacturing tolerances, and accelerated implementation. Any company determined to survive in the welding sector needs one thing above all else: maximum flexibility with minimal expenditure. But how is that even possible when the industry has been struggling with an acute shortage of skilled workers for years?
It’s hard to imagine what life would look like without skilled welders. They make, join, and repair components to meet stringent quality expectations. The demands on them have always been high, needing not only extreme dexterity and a good technical knowledge, but also concentration and a good eye for detail so they can reliably meet standards and safety requirements while producing a strong and reliable welded joint. Today, however, this is no longer enough.
Welding in transition
Today’s welders also need to know about digital welding machines, documentation systems, occupational health and safety, how to protect their health, and new materials.
“Welding tasks change on a daily basis now, so welders face the challenge of new materials, changing seam profiles, or different components every day,” explains Michael Eisterhuber, Product Line Manager at Fronius International.
Small and medium-sized companies are particularly affected by the skills shortage
Although large industrial companies often have their own training centers or find it easier to attract international skilled workers, small and medium-sized enterprises (SMEs) are increasingly coming under pressure.
Experienced welders are gradually retiring with no one to take their place.
Many young people avoid manual jobs, often due to outdated preconceptions or a lack of information about modern working conditions.
For example, some think welding is still dangerous, even though extensive health and safety measures have long been in force.
Welding automation with cobot cells
Many companies are investing in automated or robot-assisted welding processes like cobot cells to counter the shortage of skilled workers.
These systems safely take over recurring tasks and carry them out with excellent levels of precision. They lighten the load for personnel and reduce production times, freeing up staff for more complex tasks that require human expertise.
However, automation is not a sure-fire success. Although cobots have definitely become more affordable, the acquisition costs are still a factor to be considered. The solution has to be right for both the size of the business and the product range.
Versatile welding machines create flexible solutions
For SMEs in particular, cleverly designed and scalable solutions are needed, including intuitive devices that can be integrated quickly, and which genuinely lighten the workload without overcomplication. “This is precisely where our new Fortis welding machine series comes in,” asserts Eisterhuber.
The Fronius Fortis was developed as a flexible tool for everyday welding work. It’s easy to configure and doesn’t break the bank. The product range contains powerful devices in the 270 to 500 A categories, either as compact all-in-one systems or as split versions with an external wirefeeder.
“No matter which variant you opt for, all compact models can be equipped with our proven functions such as pulse welding, SynchroPulse, stitch welding, TAC tacking function, HotStart, and anti-stick,” explains Eisterhuber.
With up to 240 welding characteristics that have been specially optimized for steel, stainless steel, and aluminum, Fortis guarantees reliable results—even in demanding applications such as vertical-up seams, root passes, or thin sheet metal joints.
Ideal for vertical-up seams: A Pulse/Standard mix is now also available. Combining these two processes makes it possible to achieve up to 40% higher welding speeds without any oscillating movements.
Welding solution tailored to your needs
As the Fortis comes in different versions, you can choose the one that suits you best. Compact but with an additional external wirefeeder? The Duo variant enables the use of two wire spools and two welding torches with one single machine.
“This means that the welder can easily switch between different materials or wire diameters at the touch of a button—and all without any retooling,” reports our product expert.
The Extended (XT) variant of the Fortis is an extremely energy-efficient all-rounder for three-phase mains voltages from 200 to 600 V and single-phase operation up to max. 320 A including CEL mode.
As a result the XT machines are perfect for worldwide use, save energy thanks to their higher power factor, and offer an additional higher output characteristic curve for even greater welding performance.
Versatility over specialization or automation
“Discussions with our customers clearly show that smaller manufacturers do not need complex automated lines of equipment. They want space-saving solutions that can be integrated quickly, are easy to use, and are highly flexible,” summarizes Eisterhuber. In smaller workshops, every machine counts as two “so it makes sense to draw on multifunctionality.”
MIG/MAG, TIG, or MMA? It doesn’t matter: the all-in-one Fortis variants are available up to a power category of 500 A with the Multiprocess function and can handle all common welding processes to deliver the highest quality results.
“With Multiprocess, Fortis is not only versatile, but also fit for the future. This means that it is equipped for all possible future tasks that may not even be known today,” stresses Peter Fronius Head of System Solutions, before adding: “It is therefore the ideal and extremely flexible solution for companies with a wide range of applications.”
Shortage of skilled workers demands intuitive technology
And yet even the best machines fail if there are no specialists to operate them. Anyone using welding systems today must be able to get to grips with them quickly and without extensive training.
Our Fortis is a prime example of intuitive operation—even for less experienced users—featuring a 7-inch color display with dynamic visualizations, self-explanatory graphics, and a multilingual menu with over 30 languages. Three robust rotary and push buttons give users precise control, even when wearing welding gloves.
All key working and welding parameters are already visible on the first menu level. What’s more, custom settings can be saved, and an integrated welding parameter wizard guides you step by step to the optimal welding parameters for your application. This makes modern technology a genuine help rather than a hindrance—especially in companies where every move must be spot on.
Still undecided?
Regardless of what you go for in the end, SMEs are the backbone of industry and must not be drowned out by the competition. If you’re affected by the shortage of skilled workers too, why not take a look at our blog “Why every weld matters”?
