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Perfect welds with particularly high penetration depths and simple, convenient operation – these are the greatest advantages that the new AMADA FLW-6000ENSISe M3 has brought to Metallforum Metallbau GmbH. Thanks to this new system, the company has opened up completely new dimensions in its manufacturing activities and has strengthened its lead over the competition.
A gentle hissing noise is all that can be heard as the doors of the AMADA FLW-6000ENSISe M3 close and the welding robot moves to its position in the welding cell. Then there is a bright flickering on the monitor as the laser beam brings together speed and high precision while it welds the component on the tilt-and-turn mechanism. After a few minutes, the robot and mechanism return to their starting positions. The doors open, the operator removes the finished part and starts the next job at the AMADA 4ie controller.
A clear decision
This operation is repeated many times a day at Metallforum Metallbau GmbH in Giesen, Germany, which has been manufacturing a range of demanding products on its new AMADA FLW-6000ENSISe M3 ever since December 2024: From turnstiles for access control, for example at trade fair venues, through switch cabinets for medium-voltage installations, and on to large-volume X-ray booths with dimensions of up to three meters. For Managing Director Jens Löchel, this most recent investment in AMADA’s cutting-edge technology is a clear strategic decision: “With our AMADA machine pool, our aim at the technological level is to always stay that little bit ahead of our competitors, and that is why we made a clear decision in favor of the AMADA FLW-6000ENSISe M3 as a latest-generation fiber-laser welding cell.”
6 KW bring outstanding power
For Löchel, the greatest advantage lies in the outstanding power of the 6-kW fiber laser: “The system offers enormous depth of penetration and now enables us to weld steel and stainless steel in thicknesses of up to twelve millimeters.” The quality has ENSIS technology written all over it. “The laser-weaving technology, in which the integrated optics cause the circular, side-to-side movement of the laser beam, is particularly breathtaking. This allows us to perform outstandingly high-quality deep welding and edge rounding,” reports the Managing Director.
Reliable welding performance
This high performance is underpinned by the swiveling additional wire. Mathias Raulf, Sales Executive Northern Area at AMADA GmbH. “The additional wire that is installed as standard in the FLW welding cell is controlled via a push-pull motor and makes it possible to bridge particularly large gap sizes.” At the same time, the machine stands out for its exceptional versatility. As Löchel clearly explains: “The system simply has the best beam source and offers the best performance – at the same time, it is extremely flexible and allows us to weld everything from small parts through to housings measuring several meters.”
Fast and easy-to-use
The outstanding performance of the fiber-laser welding cell translates directly into higher productivity. At Metallforum Metallbau GmbH, this is given a further boost by the close communication between design engineers and operators, as well as by the highly qualified workforce. This brings clear value-added in everyday operation: “We’ve taken over components from a partner who was working at twelve minutes per part, whereas we only need four,” says Löchel. Thanks to the AMADA FLW-6000ENSISe M3, a normal welding operation at Metallforum Metallbau GmbH now generally only takes between 30 seconds and five minutes.
The modern AMADA AMNC 4ie controller makes a vital contribution to this efficiency. “The controller is really simple and easy to use,” stresses Löchel. And there is another important plus: “It has considerably more memory than its predecessor, the AMADA AMNC controller, meaning that there are no longer any time-consuming buffering or matrix generation operations. That saves us a lot of time and effort.”
Northern Area at AMADA GmbH
Genuine competitive advantage
Overall, Metallforum Metallbau GmbH is extremely happy with this new system, which already represents the company’s third AMADA fiber-laser welding cell. “The AMADA FLW-6000ENSISe M3 is opening up new dimensions in manufacturing for us, and in turn this is giving us access to new customers and projects. For us, it is a genuine source of differentiation and gives us a clear advantage over our competitors,” says Löchel, summing up. “AMADA is quite simply the go-to supplier in the field of automated laser welding.”
For more information on the FLW-ENSISe
Photos: Steffi Behrmann
