How can you weld in the middle of the jungle, without electricity and surrounded by wildlife? This was the challenge faced by an international team in Madagascar, where only an innovative solution could work: a battery-powered welding machine. Learn in our welding case study how thanks to the Fronius Ignis Battery, the first device of its kind designed to work in extreme conditions, it is possible to carry out critical repairs without the need for a power grid.
In the heart of Madagascar’s dense rainforests lies Parc Ivoloina—a 282-hectare protected area that is not only a zoo and research center, but also a safe haven for endangered species.
One of its many inhabitants is Calypso, a Sifaka lemur rescued from the illegal animal trade, who finally found a safe and suitable habitat isolated from all infrastructure in one of the most important nature reserves on the island’s east coast.
But even in this idyllic setting, modern welding technology plays a crucial role. Calypso and all the other animals need safe enclosures and this requires suitable equipment; no mean feat because there’s a great deal lacking in the wilderness, not least electricity.
The greatest challenge: welding without electricity
When an important quarantine enclosure at Parc Ivoloina had to be repaired and reinforced, this task became a major challenge. There was no way of completing the work without welding, but how do you weld in a location that has no power lines and no roads or tracks for vehicular access?
Tools, safety equipment, construction materials—everything had to be transported to the remote area on foot or by cart. The park managers quickly realized that they couldn’t complete the work alone and turned to their support network, the Madagascar Fauna and Flora Group (MFG). One of its leading members—the St. Louis Zoo in Missouri, USA—responded to their call for help.
The solution? Battery-powered welding machine by Fronius
Two employees of the St. Louis Zoo, Derek Strunk and Tom Sehnert, made the long journey to Madagascar to personally assist with the work. While looking for a practical solution, they had an idea: battery-powered welding machines from Fronius.
The criteria: The work required a battery-powered welder that was both easy to transport and capable of operating entirely without a mains power supply. Fronius was only too happy to help.
After a briefing, it quickly became clear that the generator needed to be as lightweight and quiet as possible, to avoid disturbing the animals. Mobile welding technology that is capable of working even in the tough conditions of the jungle was a must.
International collaboration enables battery-powered welding in the middle of the zoo
With the arrival of the battery-powered device, the lack of power was resolved. The generator that was also bought was only used to charge the batteries. Derek and Tom taught the park’s two future welders, Fanu and Laurent, the most important basics so that the pair could work independently with the equipment and welding helmets, donated by Fronius, even after their departure.
In a message to the team in St. Louis, the director of the Malagasy wildlife sanctuary described the project as “a great example of capacity development at its best.”
“The ability to simply toss the device into a golf cart and drive to the work site without any cables or generators has increased efficiency and reduced noise pollution for both animals and visitors,” says Derek Strunk enthusiastically about the battery-powered welding machines.
Setting new standards in mobile welding with the brand new Ignis Battery
The experience that we as a welding technology manufacturer were also able to gain with this project confirmed our decision to further expand our range of battery-powered welding machines. It’s clear just how crucial mobile welding technology is under genuine extreme conditions, especially in remote locations like the nature reserves of Madagascar.
As a further development of the AccuPocket, the new Ignis Battery is wireless, compact, and is setting new standards with a weight of less than 12 kilograms. Its integrated high-performance 750 Wh lithium-ion battery is fully charged in just one hour, meaning it has 85 percent more capacity than its predecessor.
No time? Then save yourself the hassle of waiting: because 40 minutes is all that’s needed to charge the battery to 80 percent. And if you’ve just got to get through the last two electrodes before the end of the day, simply plug it in for five minutes and you’re good to go.
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Freedom and flexibility: mobile welding possible anywhere with the new Ignis Battery by Fronius
Our Ignis Battery has enough power to deliver a lightning-fast charge. Half an hour of TIG welding at 100 amperes? No problem. Welding 31 electrodes, each 2.5 millimeters long, with a single battery charge? Of course. This means that mobile TIG welding is now also straightforward. The new interface is clear and easy to operate—even when wearing gloves.
In addition to the tried and tested Hot/SoftStart, anti-stick, MMA, and TIG Pulse functions, the TrackingArc feature (which ignites the arc at just 8 amperes) makes it easier to find the starting position when re-igniting. Welding errors such as insufficiently filled end-craters, notch effects, and troublesome rework therefore become a thing of the past.
Ready for your next mobile welding project with the Ignis Battery?
Whether it’s an enclosure for exotic Sifaka lemurs in a Madagascan zoo or simply a rabbit hutch in your own garden—mobile welding can make the difference everywhere. With the Ignis Battery, you’re free of cables and limits, and you’re ready to fearlessly take on any project.
Looking for some inspiration for your next welding project? Check out our blog to discover 10 creative ideas to tackle with your welding machine.
