TIG 3D Welding System for High-Productivity Metal Deposition
With InFocus 3D, you can achieve automated TIG cladding with high material throughput – for large-area wear protection, the repair of massive metal components and the additive build-up of large structures. The system combines proven TIG technology with three individually controllable wires and intelligent process control.
Unlike laser-based ProFocus systems, InFocus 3D is particularly suitable for applications where high material deposition, direction-independent process control and cost-effectiveness are the main priorities. This allows even large-scale welding tasks to be carried out automatically and reproducibly.
Your benefits at a glance
| • | High melting rates of up to 12 kg/h with hot-wire option |
| • | Three individually controllable wires for productive material deposition |
| • | Stable TIG arc for reproducible welding results |
| • | Direction-independent wire feeding for flexible motion control |
| • | Automatic height control and camera-based process monitoring |
| • | Modular integration into robotic and multi-axis systems |
Challenges in manufacturing
High material deposition places particular demands on productivity, welding quality and automation. Conventional processes often reach their limits, especially when processing large components or applying thick protective coatings:
| • | Limited deposition rates with single-wire welding |
| • | Inconsistent welding results with manual processing |
| • | Time-consuming large-area coating and repair processes |
| • | Complex coordination of wire feeding, heat input and motion control |
| • | Laser-based processes are not always the most economical solution for large-volume deposition |
What is needed are powerful welding processes that combine high material throughput with industrial process stability.
The solution: InFocus 3D
High deposition rates – controlled and automated
InFocus 3D combines the concentrated TIG arc of the Kjellberg InFocus torch with triple, individually controllable wire feeding. The optional hot-wire technology increases the melting rate, while OSCAR PLT process control coordinates the individual components.
What this means for you:
| • | Higher productivity through parallel material feeding |
| • | Adjustable deposition rates through cold-wire and hot-wire operation |
| • | Flexible material combinations through individual wire control |
| • | Reduced operator intervention through automated processes |
| • | Straightforward integration planning for existing manufacturing systems |
Technology & system design
Three wires, one stable TIG process
InFocus 3D uses tungsten inert gas welding (TIG). An electric arc between a non-consumable tungsten electrode and the workpiece creates the weld pool, while an inert shielding gas protects the welding area from the surrounding atmosphere.
The Kjellberg InFocus torch generates a concentrated, stable arc. Up to three filler wires are fed independently into the weld pool. With optional hot-wire technology, additional energy is introduced directly into the filler material, enabling higher melting rates.
Direction-independent wire feeding allows flexible welding paths without the need to constantly realign the wire feed.
Technological benefits
| • | Triple wire feeding with individually controllable filler wires |
| • | Melting rates of up to 12 kg/h with a suitable hot-wire configuration |
| • | Solid and flux-cored wires with diameters of 0.8–1.6 mm |
| • | Weld bead widths of 6–14 mm within the documented technical performance range |
| • | Individual wire feeding enables in-situ alloying with suitable materials |
| • | Concentrated TIG arc with high process stability |
| • | Customizable shielding gas nozzle caps for local shielding gas coverage |
The achievable values and coating properties depend on the material, process parameters and system configuration.
Modular system design
InFocus 3D combines torch technology, wire feeding, power supply and process control in a modular cladding system. The components are configured to suit the specific welding task and can be integrated into existing robotic and multi-axis systems.
System components and expansion options
| • | Process head with Kjellberg InFocus additive welding torch and three wire feed units |
| • | Main welding power source and optional hot-wire power sources |
| • | Control cabinet with bus-based or hardwired signal connections |
| • | Integrable Cavitar welding camera for monitoring the welding process |
| • | Optional laser line scanner for component scanning |
| • | Individually configurable control and regulation functions |
In the documented configuration, the process head weighs approximately 15 kg including the torch. This provides a specific planning parameter for integration into suitable motion systems.
Process know-how & control
High material deposition requires more than powerful welding technology. The key is the coordinated interaction of arc energy, wire feeding, torch distance, motion control and material properties.
Support from OSCAR PLT
| • | Coordination of welding current, wire feed rate and welding speed |
| • | Selection and design of cold-wire and hot-wire processes |
| • | Development of coating, repair and multi-layer deposition strategies |
| • | Configuration of individual wire feeds for suitable material combinations |
| • | Optimization of heat input, penetration, dilution and layer geometry |
| • | Evaluation of welding results and component properties |
This allows the TIG 3D process to be specifically tailored to the required deposition rate and the properties of the individual component.
Software & process control
The OSCAR PLT TIG 3D process control system coordinates wire feeding, welding technology and motion sequences. Relevant process parameters can be set and monitored through the OSCAR PLT TIG 3D HMI. Automated control functions support reproducible manufacturing, even during multi-layer and longer welding processes.
Process control functions
| • | Individual control of up to three wire feeders |
| • | Hot-wire control for adjusting additional energy input into the filler material |
| • | Automatic height control to maintain a constant torch-to-workpiece distance |
| • | Start-stop synchronization with the robot or motion system |
| • | Camera-based process monitoring with the appropriate system configuration |
| • | Intuitive user interface for setting and monitoring key process parameters |
Depending on the system configuration, additional functions for component scanning and digital process planning can be integrated. This allows more extensive manufacturing and repair tasks to be systematically prepared and carried out automatically.
Applications
For large-volume repairs, wear protection and additive manufacturing
InFocus 3D is particularly suitable for applications where large amounts of metal or wide functional coatings need to be deposited economically. The individually controllable wires also open up possibilities for processing different filler materials and in-situ alloying with suitable material combinations.
Typical fields of application
| • | Repair of large metal components, such as crusher rollers and heavily stressed machinery components |
| • | Large-area wear protection coatings, for example on sliding shoes |
| • | Additive manufacturing and rebuilding of large-volume metal structures |
| • | Reproduction of metal components that are no longer available, based on scans or design data |
| • | Development and testing of functional coatings using different filler materials |
Service & integration
From welding task to productive TIG 3D process
OSCAR PLT supports you from the initial assessment of your welding task through to productive operation. The key factors are the component, required deposition rate, material and existing system environment. Together, we develop a coordinated solution combining welding technology, process control and system integration.
Services
Would you like to find out whether InFocus 3D is suitable for your application?
Talk to us about your component, the required material deposition and your manufacturing requirements. Together, we develop the right process and system solution – for an economical, reliable and easy-to-control TIG 3D process.
With three wires and optional hot-wire technology, InFocus 3D achieves high melting rates for large-volume deposition processes.
Individually controlled wire feeders enable high deposition rates and the targeted combination of suitable filler materials.
The Kjellberg InFocus torch combines a concentrated arc with proven TIG technology for reproducible welding results.
Automatic height control, synchronized process sequences and the OSCAR PLT TIG 3D HMI simplify process operation.
Do you have questions about our company, our products or our services? Then you've come to the right place.
In documented cold-wire operation, InFocus 3D achieves deposition rates of approximately 1.6 to 3.3 kg/h. With a suitable hot-wire configuration, melting rates of up to 12 kg/h are possible. The actual achievable rate depends on factors such as material, wire feeding and process parameters.
The three wire feeders can be controlled individually. This enables high material deposition rates and the targeted combination of suitable filler materials. It also allows in-situ alloying, where the material composition can be influenced during the welding process.
InFocus 3D features a modular design and can be combined with suitable robotic and multi-axis systems. OSCAR PLT process control supports individual wire feeding, automatic height control and start-stop synchronization with the motion system. OSCAR PLT provides support with system design, integration, commissioning and process optimization.
InFocus 3D is a WIG/TIG-based 3D cladding system from OSCAR PLT for automated coating, repair and additive manufacturing. A Kjellberg InFocus torch generates a stable arc, while up to three individually controlled wires are fed into the weld pool. This enables controlled deposition of large amounts of material.
InFocus 3D uses WIG/TIG technology with up to three wires. The system is particularly suitable for large-volume deposition, thick coatings and high melting rates. ProFocus, on the other hand, is based on laser-directed energy deposition (Laser-DED) and is designed for precise material deposition, finer contours and controlled heat input. The choice depends on the component, material and production requirements.
InFocus 3D is designed for solid and flux-cored wires with diameters ranging from 0.8 to 1.6 mm. The individually controlled wire feeders also allow suitable material combinations to be investigated for functional coatings. The selection of filler materials depends on the specific application and process requirements.
ProFocus is an intuitive, modular laser welding system that brings modern laser cladding into everyday production—enabling automated repair, coating and additive build-up of metal components with reduced material use, minimal rework, and stable, reproducible quality.
The compact version combines all the benefits of ProFocus technology in an innovative laser head whose efficient design enables completely new applications and geometries.
Turnkey laser cell for laser cladding, metal 3D printing, repair and coating of small to medium-sized components – compact, flexible and easy to use.
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