Capabilities

StirLight provides end-to-end Friction Stir Welding services, from process development to low and medium-volume production. Our in-house capabilities help partners accelerate FSW R&D and deliver UK-based manufacturing with confidence.

StirLight FSW Gantry SuperStir
StirLight FSW Gantry SuperStir
StirLight Robotic FSW System
StirLight Robotic FSW System

Key Specs

Gantry FSW – ‘Greta’

Platform: ESAB SuperStir™

Overview: Greta is StirLight’s heavy-duty FSW platform, designed for large and thick-section components across demanding industries. With robust force control, high travel speeds, and flexible tooling setups, Greta enables full-scale process trials and structural joining in aluminium, copper, steel, and more.

Robotic FSW – ‘Agatha’

Platform: ABB IRB 8700-800 Industrial Robot with ESAB EWH 50-FSW Head

Overview: Agatha is StirLight’s agile robotic FSW system, ideal for small-to-medium parts, curved welds, and complex geometries. She enables rapid prototyping and flexible R&D.

Gantry FSW process capabilities:

Materials: All aluminium alloys (up to 50mm thick) , copper, titanium, steel, and dissimilar joints

Travel Speed: 30–5000 mm/min (material, tool, and thickness dependent)

Clamping & Fixturing: Custom fixtures supported, gantry design ensures rigidity

Robotic FSW process capabilities:

Materials: All aluminium alloys

Travel Speed: Optimised for high-speed welding in thin aluminium

Tooling & Fixturing: Compatible with adaptable modular fixturing and integrated cooling

Gantry FSW Extended Capability

Supports welding of extended panel builds >10 metres in length (~2m width) via modular panel handling and repositioning. This is ideally suited for:

  • Aerospace structures
  • Truck beds and chassis rails
  • Marine bulkheads
  • Energy systems and cooling assemblies

Robotic FSW Extended Capability

Supports extended straight welds up to 5 metres with minimal changes to the table setup. Its robotic flexibility makes it ideal for:

  • Lightweight structural panels
  • Battery and thermal management enclosures
  • Liquid-cooled cold plates
  • Aerospace seat rails and floor assemblies
  • Automotive body-in-white components
  • Defence and electronics casings

Gantry FSW Applications

  • FSW process development in high-integrity materials
  • Manufacture of prototypes and small production runs
  • Validation of novel joint designs and dissimilar material welds
  • Heavy-duty tool testing and parameter optimisation
  • Real-time quality assurance trials and digital twin research

Robotic FSW Applications

  • Process development in thin aluminium alloys
  • Prototype and short-run production of lightweight components
  • Trials requiring complex or non-linear weld paths
  • Agile projects where flexibility and speed are critical

Do you want the full capabilities sheet of these systems?

We have put together a detailed PDF including technical specs, tooling, force limits and capabilities.

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Let’s explore what FSW can do for you

Whether you are prototyping, developing a new process, or scaling production, we will help you get there faster with expert Friction Stir Welding support.

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