Which applications and components is the OSCAR WeldingCell suitable for?

The OSCAR WeldingCell is suitable for restoring worn component areas, applying functional coatings and additively manufacturing metal structures and components.

The scanner, robot and positioner are particularly useful for processing complex contours and recurring tasks. The component dimensions, weights and geometries that can be accommodated depend on the specific cell configuration. The suitability of the base material, filler material and processing strategy is assessed for each application and can be evaluated through a feasibility study.

What is the OSCAR WeldingCell?

The OSCAR WeldingCell is a turnkey, configurable robotic cell for laser metal deposition, repair, coating and additive manufacturing.

It combines the ProFocus laser system with an industrial robot, a tilt-and-turn positioner, a component scanner and digital toolpath planning in an integrated solution. While ProFocus provides the welding technology, the WeldingCell also includes the motion, scanning and cell equipment required for automated processing.

What is ProFocus by OSCAR PLT?

ProFocus is a modular laser cladding system for wire and powder, particularly suitable for repair, coating and metal additive manufacturing. ProFocus enables controlled material deposition with minimal penetration, stable process conditions and reproducible results — even with complex component geometries and materials that are difficult to weld.

Can the OSCAR WeldingCell be adapted to individual requirements?

Yes. The OSCAR WeldingCell is configured to suit the components and processing tasks involved.

Options include the robot, tilt-and-turn positioner, cell dimensions, workholding fixtures, scanner and process equipment. Material feeding, software functions and integration into existing production workflows are also tailored to the application.

OSCAR PLT supports component selection and develops a suitable process strategy for repair, coating or additive manufacturing.

What applications is ProFocus suitable for?

ProFocus is suitable for laser cladding, component repair, functional coatings and additive manufacturing processes. Typical applications include reconstructing worn component areas, selectively reinforcing surfaces, or manufacturing, reproducing and repairing metallic structures with low material input.

How does ProFocus reduce material consumption and post-processing?

ProFocus is characterized by controlled material deposition and the ability to produce very fine weld beads. The wire is used 100% and deposited close to the final contour with low dilution and minimal penetration. This results in less scrap, reduced thermally induced distortion, less grinding effort and shorter post-processing times.

What role does process control play in ProFocus?

The control and regulation algorithms of ProFocus are essential for a reproducible, automated laser cladding process. Without controlling relevant parameters such as material deposition, motion control, energy input and process data logging, the wire-based process would not function intuitively. The algorithms ensure outstanding processing results even with complex geometries, limited accessibility and materials that are difficult to weld.

Can ProFocus be used with demanding materials?

Yes. Thanks to controlled energy input, ProFocus can be used for laser cladding with a wide range of metallic materials — from cast materials to free-cutting steels, tool steels and titanium. Adapted process parameters and the required process expertise can be developed in feasibility studies and then transferred to the customer.

How is ProFocus integrated into existing production environments?

ProFocus has a modular design and can be combined with laser scanners, sensor systems, robot systems, positioning technology and a laser safety cell, depending on the application. OSCAR PLT provides support from feasibility assessment and system design through to commissioning and productive integration into existing manufacturing processes.

How does the OSCAR WeldingCell help reduce manufacturing and repair costs?

The OSCAR WeldingCell reduces manual tasks through a digitally connected process chain covering component scanning, data processing, toolpath planning and automated laser metal deposition.

Targeted, near-net-shape material deposition can reduce filler material consumption and subsequent machining requirements. For high-value components, repairing worn areas also allows the existing part to remain in use. The achievable savings depend on the application, the previous manufacturing or repair method and equipment utilisation.

How does the digital process chain from scanning to welding work?

A laser scanner first captures the existing component geometry. The scan data is used to generate a point cloud, which forms the basis for CAD/CAM-based process planning. Suitable deposition toolpaths are then generated and executed by the robotic system using the ProFocus process head. The tilt-and-turn positioner helps orient the component for processing. Connecting these steps digitally reduces manual data transfers and makes recurring tasks easier to prepare. The level of automation is tailored to the application and cell configuration.

Which functions help maintain a stable deposition process?

The ProFocus process control system uses coordinated assistance functions to manage the interaction between energy input, wire feed and working distance. StartControl enables automatic start-point detection and coordinated start-stop sequences. WireWatcher monitors the wire process to help prevent uncontrolled wire break-offs. HeightControl regulates the working distance and supports consistent layer build-up.

Additional functions include anti-balling and anti-sticking assistance, camera-based process observation, component temperature monitoring and process data logging. The specific range of functions is defined during system configuration.

What distinguishes ProFocus Compact from ProFocus?

ProFocus Compact brings the proven ProFocus technology into a particularly slim and lightweight design. This makes the system especially suitable for applications where limited space, good accessibility or flexible integration into existing production environments are important.

Can ProFocus Compact be integrated into existing CNC machines or robotic systems?

Yes. ProFocus Compact is designed for flexible integration into existing production environments, such as CNC machines, robotic systems or mobile systems. This allows existing equipment to be expanded and used more efficiently.

What are the benefits of the compact design?

The compact design improves accessibility, reduces space requirements and makes integration easier to plan. This allows ProFocus Compact to be used even where larger systems would be too complex or difficult to implement due to space limitations.

Is ProFocus Compact also suitable for companies new to laser processing?

Yes. ProFocus Compact lowers the barrier to entry because the system is compact, manageable and designed for practical integration. OSCAR PLT also supports customers with feasibility checks, system design, commissioning and training.

How does ProFocus Compact help reduce downtime?

Damaged or worn components can be rebuilt precisely instead of being completely replaced. This reduces waiting times for spare parts, extends the service life of valuable components and helps shorten unplanned downtime.

What is the ProFocus LaserCell Compact?

The ProFocus LaserCell Compact is a compact, turnkey laser cell for laser cladding, metal 3D printing, repair and coating of small to medium-sized components. It combines ProFocus technology with a work area, user interface and coordinated system environment.

How does the ProFocus LaserCell Compact differ from ProFocus Compact?

ProFocus Compact is a compact system solution for flexible applications and integration into existing production environments. The ProFocus LaserCell Compact, by contrast, is a complete, enclosed system solution with its own laser cell, work area and user interface.

How does the ProFocus LaserCell Compact differ from the OSCAR WeldingCell?

The OSCAR WeldingCell is designed for larger, automated processes with a robot cell and digital process chain. The ProFocus LaserCell Compact is the compact laser cell for small to medium-sized components, feasibility studies and applications where a large automated system is not required.

Who is the ProFocus LaserCell Compact suitable for?

The ProFocus LaserCell Compact is suitable for companies that want to use a compact laser cell for laser cladding without planning a large custom system. It is especially useful for small to medium-sized metal components, limited production space and applications that require a turnkey, easy-to-access solution.

What are typical applications for the ProFocus LaserCell Compact?

Typical applications include repairing worn or damaged components, coating heavily stressed surfaces, additive manufacturing of small to medium-sized metal components, feasibility studies and process development.

Which applications is ProFocus Compact suitable for?

ProFocus Compact is suitable for repair welding, laser cladding, coating and metal additive manufacturing. Typical applications include rebuilding worn component areas, protecting heavily stressed surfaces against wear and selectively building up new contours.

What is InFocus 3D and how does the WIG/TIG 3D welding system work?

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.

How does InFocus 3D differ from ProFocus?

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.

What melting rates can InFocus 3D achieve?

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.

What are the benefits of the triple wire feed in InFocus 3D?

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.

Which wire materials can be processed with InFocus 3D?

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.

How is InFocus 3D integrated into existing production systems?

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.

What are the advantages of wire compared with powder?

Wire-based laser metal deposition offers high material efficiency, easy handling and very low material loss. Unlike powder-based processes, the filler material is supplied directly as wire, which simplifies material handling and avoids powder overspray. Wire is widely available in standardized welding grades and is particularly suitable for automated repair, coating and additive manufacturing processes.

For a more detailed comparison of the processes as well as information on applications, materials and process parameters, see our process knowledge page on Laser Metal Deposition with Wire.

What is InFocus and how does it work?

InFocus is a system for automated high-performance TIG welding. The combination of torch design, electrode and intensive cooling creates a concentrated, stable arc. This enables narrow, deep welds and higher welding speeds than conventional TIG welding.

How does InFocus differ from conventional TIG welding?

InFocus concentrates the arc energy more strongly and operates with increased arc pressure. Depending on the welding task, this enables higher welding speeds and deeper penetration while maintaining a limited weld width. Under suitable conditions, single-pass keyhole welding is also possible.

Which applications is InFocus suitable for?

InFocus is suitable for automated joining applications, including longitudinal seams on sheets and profiles, as well as circumferential seams on tubes and rotationally symmetrical components. Further applications include flange joints, corner joints, joints between components of different thicknesses and continuous welding processes on thin-walled components.

Which materials can be welded with InFocus?

InFocus can weld materials including high-alloy steels, duplex steels, nickel-based alloys, copper and titanium. InFocus Pluspole is available for aluminium. The appropriate variant and process configuration depend on the material, sheet thickness and joint geometry.

What is the difference between InFocus 500 and InFocus 1000?

InFocus 500 is a slim torch design for welding currents up to 500 A and applications with limited access to the component. InFocus 1000 offers a torch current capacity of up to 1,000 A and is designed for deep welds and high-performance welding processes. The choice depends on the welding task, available space and required performance.

What is InFocus Pluspole and when is it used?

InFocus Pluspole is a variant for welding aluminium. It operates with direct current and an electrode connected to the positive pole (DCEP). The cathodic arc attachment on the workpiece helps remove the oxide layer. This variant is suitable for automated aluminium welding; process conditions are adapted to the material, sheet thickness and joint geometry.