FSW Seamer: a custom-made gantry for Friction Stir Welding applications
In response to growing industrial demands for quality, productivity, and repeatability, Friction Stir Welding (FSW) has become an essential technology. To ensure that all types of industrial applications can benefit from the advantages of FSW, MITUSA and Stirweld have combined their expertise to develop the FSW Seamer. This high-performance, complete Friction Stir Welding solution is specifically designed to adapt to the needs of each assembly application. Discover this custom-made automated machine, which integrates Stirweld’s FSW head.
MITUSA and Stirweld: welding experts serving the industry
To address growing industrial challenges in performance and reliability, MITUSA and Stirweld leverage their respective welding expertise. Thanks to their complementary strengths, their collaboration led to the creation of the FSW Seamer, a custom-made Friction Stir Welding solution.
MITUSA, specialist in welding and rolling automated gantries
MITUSA is a U.S.-based manufacturer specializing in high-precision welding automation solutions and handling systems.
The company relies on strong in-house expertise in engineering, machining, and manufacturing to design both standard and custom equipment.
With a highly experienced team and the integration of advanced welding technologies (TIG, MIG, plasma), MITUSA develops high-performance solutions to optimize industrial processes worldwide.
Stirweld, friction stir welding specialist, FSW heads and accessories manufacturer
Stirweld is a French company specializing in friction stir welding (FSW), recognized for its expertise in designing innovative welding heads and mastering the process (design assistance, prototyping, clamping system, training), with Stirweld Inc. being their American subsidiary.
Through a performance-driven and integration-friendly approach, Stirweld enables manufacturers to access FSW via solutions adaptable to existing equipment.
By combining technological innovation with application support, the company helps improve weld quality, process repeatability, and production efficiency.
MITUSA and Stirweld: complementary expertise
The FSW welding heads, developed and manufactured by Stirweld, have been designed to be installed on CNC machines, gantries or robotic systems. This specific feature makes FSW technology accessible to a wide range of manufacturers.
However, for some industrial projects, the applications involve specific constraints that require a tailored approach, an area where MITUSA specializes.
The collaboration between Stirweld and MITUSA therefore emerged naturally from this observation. By combining their complementary expertise, the two companies offer the FSW Seamer: a complete and integrated friction stir welding solution, from tooling to machine, custom-designed to meet specific assembly requirements.
This tailored approach enables manufacturers to fully leverage the potential of FSW across sectors such as defense, space, automotive, aerospace, energy, shipbuilding, and rail.
FSW Seamer: a custom-made solution designed for industrial performance
The result of collaboration between MITUSA and Stirweld, the FSW Seamer was designed to meet the constraints of the most demanding industrial environments. This complete solution simplifies FSW integration while ensuring high levels of performance and repeatability.
A complete FSW system for industrial production
The FSW Seamer combines a custom-made automated machine developed by MITUSA with Stirweld’s FSW head.
This collaboration delivers a fully integrated FSW solution meeting industrial requirements in terms of quality, repeatability, and performance.
This linear welding system, 1.80 meters long (length to be adapted on demand), produces high-quality welds with excellent consistency, even in constrained production environments. It integrates all necessary components: welding head, clamping system, motorized axes, and control system.
| FSW Seamer features | FSW Seamer options |
| ✔ Single pass welds for thicknesses up to 12mm (.47’’) ✔ Weld force range up to 25kN ✔ Fully integrated HMI touch screen ✔ Productivity monitoring & workforce accountability ✔ Save uo to 1,000 weld schedules ✔ Programs downloadable to USB for backup ✔ Spindle speed up to 3200 RPM ✔ Data logging control for complete traceability | ✔ Multiple FSW tool options ✔ Edge alignment devices ✔ Riser for clearance of large diameter parts ✔ Material loading and unloading solutions ✔ Weld camera for live monitoring |
An intuitive software for ease of use
The FSW Seamer integrates a control system with embedded software designed to make FSW accessible and easy to use.
Up to 1,000 welding programs can be stored, enabling efficient management of multiple production configurations.
The user interface is highly intuitive: simply select the material thickness, and the system automatically suggests parameters such as penetration depth and travel speed.
These settings provide a reliable starting point for production. Fine adjustments remain possible to account for material variations and optimize weld quality.
This approach ensures both ease of use and full process control.
A modular, mobile and adaptable machine, that can be customized to welding applications (circumferential, orbital, flat)
The FSW Seamer stands out thanks to its highly modular and integrated design.
All key components are embedded within the machine: drives, motors, water cooling system, and control system.
This compact architecture simplifies installation and operation. The machine is designed to be easily transportable, with dedicated lifting points allowing it to be moved as a single unit. Once positioned, it only requires connection to power supply and compressed air to resume operation.
Beyond mobility, the FSW Seamer offers great flexibility:
- Horizontal to vertical welding
- Welding of cylindrical parts (circumferential welding) or flat parts (machine to be custom-made)
Thanks to MITUSA’s in-house engineering expertise, the machine can be fully adapted to specific application requirements, making it a scalable solution aligned with industrial challenges.
How the FSW Seamer will benefit your assembly project?
With the FSW Seamer, manufacturers gain access to a complete, custom-made engineered solution designed to improve weld quality, secure production processes, and optimize overall performance—while benefiting from expert support.
Proven FSW technology backed by a recognized expert
Stirweld, a recognized player in friction stir welding, supplies FSW heads already used by more than 90 industrial companies worldwide, across demanding sectors.
The FSW Seamer fully leverages Stirweld’s expertise, and the advantages of Friction Stir Welding:
- High weld quality (no porosity)
- Low part deformation (solid-state process, no melting)
- Clean and cost-effective process (no filler material or shielding gas)
- High repeatability
- Increased productivity
- Ability to weld challenging materials (particularly well-suited for aluminum)
- Enhanced traceability and process control
The integration of this technology into a machine designed by MITUSA ensures a solution that is both high-performing and reliable.
FSW tool availability ensures production continuity
In an industrial environment, every production stoppage comes at a cost. Ensuring the availability of FSW tools is key.
Stirweld stands out for its ability to quickly supply FSW tools, thanks to a well-structured and readily available inventory. This responsiveness helps to:
- Reduce downtime,
- Secure production cycles,
- Ensure better operational continuity.
This is a critical factor for manufacturers operating under demanding requirements in terms of lead times and productivity.
Technical support to secure your project
Beyond the equipment itself, the success of an FSW project also relies on process expertise.
As part of the partnership, Stirweld and MITUSA teams work closely together to support each project, from design to commissioning. This support enables:
- Adaptation of the solution to specific application constraints,
- Optimization of welding parameters,
- Secure industrialization.
This approach ensures a controlled integration of the FSW process and allows manufacturers to fully leverage the technology.
Want to learn more about the FSW Seamer?
Our FSW specialists are at your service to assess your needs as part of a custom equipment project.
