Prototype Welding & Fabrication

TIG, MIG, Laser.
Aluminum, steel,
titanium.

Certified welders working to AWS D1.1, D1.2, D1.6 and aerospace D17.1 procedures. From sheet-metal chassis welds to flight-qualified titanium fuel lines to EV battery pack busbars. Clean, certified, documented.

Welding Quote Sheet metal

01 · Processes

Welding processes we run.

TIG / GTAW

Al · SS · Ti · clean

Gas Tungsten Arc — slow, clean, precise. Our default for thin-section aluminum, stainless and titanium. Visible cosmetic welds, minimal distortion.

MIG / GMAW

Steel · Al production

Gas Metal Arc — faster than TIG. Standard for steel production welding, thick aluminum. Consumable wire feed.

Laser Welding

Thin · deep narrow

Fiber laser welding for thin sections (< 3 mm) with minimal distortion. Deep narrow welds (aspect > 3:1) impossible with arc processes.

Resistance Spot

Sheet metal stacks

Pressure + current through sheet metal joints. Fast, high-volume, ideal for 0.5–3 mm thick sheet stack-ups.

Ultrasonic

Cu · Al · battery

High-frequency vibration welds pure copper and aluminum without melting. Standard for battery cell-to-busbar connections.

Brazing

Dissimilar metals

Copper, silver, or bronze braze filler at 650–900 °C. Joins dissimilar metals — copper to steel, steel to stainless, aluminum to copper.

Flux-core FCAW

Outdoor / heavy

Self-shielding wire for outdoor and heavy structural welds. Used on weldments and heavy-duty frames.

TIG Orbital

Tube welding

Automated orbital TIG for pipe and tube circumferential welds. Critical for pharmaceutical, aerospace fluid systems.

Stud Welding

Studs to sheet

Capacitor-discharge or arc-stud welding of threaded studs to plate. Common on enclosure hardware, grounding connections.

02 · Typical work

Welded assemblies we ship.

EV battery enclosures

Al 5052 TIG welded tray assemblies with integrated cooling channels

Stainless food-grade

304/316L sanitary weldments with polished Ra 0.4 µm weld interior

Aerospace fuel lines

Ti Gr.2 orbital TIG welded tube assemblies with X-ray inspection

Industrial frames

Steel 4140 TIG/MIG welded frames for CNC, industrial machinery

Battery busbar assemblies

Ultrasonic welded Cu and Al busbars for EV and energy storage

Pressure vessels

Low-pressure tanks and vessels (ASME through partner for code work)

Exhaust & hot section

Inconel 625 TIG welded exhaust systems, aerospace hot section

Sheet metal chassis

Spot-welded aluminum and steel chassis, control cabinets, enclosures

Marine hardware

316L TIG welded cleats, rigging, marine hardware with polished welds

FAQ

Welding questions.

TIG (GTAW) for aluminum, stainless, titanium — precise, clean, minimal distortion. MIG (GMAW) for steel and aluminum production welding — faster than TIG, adequate for structural. Laser welding for thin-section precision and deep narrow welds. Resistance spot welding for sheet metal stack-ups. Ultrasonic welding for small aluminum (battery tabs, busbars). Brazing for joining dissimilar metals.

AWS D1.1 (steel structural), D1.2 (aluminum structural), D1.6 (stainless), D17.1 (aerospace). Welders qualified per AWS B2.1 procedures. For aerospace work, procedures documented and welders qualified to specific specifications. ISO 3834 quality requirements for fusion welding workflow.

Yes. Titanium welding requires special precautions — argon gas purging inside the joint, cooling under inert atmosphere, color check for contamination (straw color acceptable, blue is overheated, purple/grey indicates contamination requiring rework). We maintain dedicated titanium welding stations with glove-box purge capability for critical aerospace and medical work.

Low-pressure only (below 15 PSIG uncertified). For ASME pressure vessels, we work with ASME-certified partners to weld, inspect, and X-ray per Section VIII Division 1. Typical project: we machine components, certified shop welds and X-rays per ASME code. Hydrostatic testing available to 500 PSIG through partner.

Yes — this is a regular EV workstream. Ultrasonic welding for copper and aluminum busbar-to-cell connections (preferred method for Li-ion cells). Laser welding for busbar-to-busbar joints. Resistance spot welding for steel can tabs. Inspection via CT scan available for weld verification on critical battery pack assemblies.

Multiple strategies: tack-weld sequence to balance shrinkage, skip-welding to distribute heat, tempered distortion allowance in parent-part design, fixturing with clamping during cooling, stress relief heat treatment after welding (for 4130 steel, aluminum 5xxx/6xxx welds), peen weld toes for fatigue improvement. For critical straightness, post-weld machining of key surfaces is specified.

TIG, MIG, Laser.Aluminum, steel,titanium.