Custom Special Machines (Laser Welding Systems)

Custom special machines are engineered systems designed to perform specific industrial tasks not achievable with standard off-the-shelf machinery. These machines are typically developed for unique production requirements, with applications in sectors such as automotive, aerospace, electronics, and medical devices. One notable category within this domain is custom laser welding systems, which utilize laser technology to join materials with high precision and efficiency.

Overview

Custom special machines differ from general-purpose industrial equipment in that they are tailored to meet the unique specifications of a particular manufacturing process or product. The customization may include structural design, automation levels, material handling integration, control interfaces, and the specific type of laser source used. These machines are commonly developed in close cooperation between the machine builder and the end user.

Laser Welding Technology

Laser welding is a non-contact welding technique that uses a focused laser beam to join materials, typically metals or thermoplastics. It is known for its ability to produce narrow, deep welds with minimal thermal distortion. The process can be automated, making it suitable for high-precision and high-throughput industrial applications.

Key characteristics of laser welding include:

• High precision: Suitable for welding fine or intricate components.
• Minimal heat-affected zone (HAZ): Reduces warping and maintains material properties.
• Repeatability: Consistent results in mass production.
• Versatility: Compatible with a variety of materials, including stainless steel, aluminum, and titanium.

Features of Custom Laser Welding Systems

Custom laser welding systems are typically equipped with the following features:

• Tailored mechanical and structural design based on specific part geometry and production goals.
• Automation modules, including robotic arms, conveyors, and part positioning systems.
• Programmable control systems (e.g., CNC or PLC) for managing laser parameters, movement, and sequencing.
• Safety enclosures and real-time monitoring to ensure operator protection and process stability.
• Modular configurations allowing future upgrades or adaptation to new product lines.

Industrial Applications

Custom laser welding systems are used across multiple industries:

• Automotive industry: Welding of chassis components, gear assemblies, battery housings, etc.
• Medical technology: Fabrication of surgical tools, implants, and device enclosures.
• Aerospace: Welding of high-strength lightweight alloys for aircraft components.
• Electronics: Assembly of enclosures, sensors, and connectors requiring precision and thermal control.
• Tool and die making: Joining of complex tooling components with minimal distortion.

Notable Manufacturers

Several companies specialize in the design and production of custom laser welding machines. Among them is Sigma Laser GmbH, a German manufacturer known for offering bespoke laser systems that integrate cutting-edge fiber laser sources, advanced control technology, and robotic automation. Their product line includes turnkey solutions for various laser processing tasks, including welding, marking, and engraving.

Advantages

Custom laser welding machines provide several benefits over standard solutions:

• Increased process efficiency due to system optimization.
• Enhanced product quality through precise and consistent welding.
• Reduced downtime and scrap rates in manufacturing.
• Improved safety and ergonomics in production environments.
• Scalability and long-term flexibility for changing production needs.

Simass Base Unit: Wikipedia‑Style Entry

Simass Base Unit is a modular core of Sigma Laser GmbH’s Simass family of automated laser welding systems. Designed for high-volume industrial applications, it provides a configurable foundation adaptable to a wide range of welding tasks.

Overview

The Simass Base Unit comprises a rigid frame supporting three digitally controlled linear axes (X, Y, Z) with travel distances:

• X-axis: up to 1,010 mm
• Y-axis: up to 1,110 mm
• Z-axis: up to 510 mm

It includes necessary feed lines and interfaces, enabling integration with customized handling, loading, and feeding modules suited to specific production requirements.

Modular Architecture

The Base Unit supports several interchangeably attachable modules to enhance functionality:

1. Rotate Module

1. • Features a precision rotary table (diameter up to 1,500 mm), either fixed-speed or programmable.
   • Enables loading/unloading while welding occurs, optimizing cycle time.
   • Equipped with independent zones for loading and welding, and optional pneumatic connections

2. Slide Module

1. • Designed for larger, tubular, or elongated components.
   • Uses three motor-driven slides and six axes, allowing loading/unloading during welding.
   • Supports parts up to 500 mm diameter and 1,500 mm length, and accommodates both horizontal and vertical welding orientations

3. Powder Module

1. • Enables automated addition of welding powder for repair or buildup processes.
   • Can be mounted in place of other modules as needed

Control & User Interface

• Multifunction joystick: Offers analog and digital input, including Vmax mode for rapid axis movements, coordinate inversion, fourth-axis activation, automatic pulse control, and programmable keys
• Removable magnetic display: Includes 50 parameter memory slots, redundant controls, and connectivity for path control software (Sigomatic), enabling easy recall of welding sequences, viewing of real-time data, and recording of pulse rates and operating hours

Applications

Suitable for diverse industries, including:

• Tool and mold making
• Medical and surgical device manufacturing
• Shipbuilding and heavy industry
• Consumer electronics
• Aerospace components
• Jewelry production

Significance

The Simass Base Unit provides a highly flexible, automated platform capable of integrating different modules for specific workflows. Its robust axes, modular adaptability, and precise control capabilities make it ideal for high-volume, repeatable, and customizable laser welding tasks in demanding manufacturing environments.

Related Systems

• Simass Rotate: Rotary-table variant, enhancing productivity through continuous component indexing
• Simass Slide: Configuration tailored for long or large workpieces with simultaneous load/unload capability

Simass Base Unit – Modular Laser Welding Platform for Precision Manufacturing :: customer object handling section

Looking for a flexible and high-performance laser welding solution tailored to your production needs? The Simass Base Unit by Sigma Laser offers a powerful modular foundation for automated laser welding applications across multiple industries — from tool and mold making to medical device manufacturing.

What Is the Simass Base Unit?

The Simass Base Unit is a customizable laser welding platform equipped with three high-precision CNC-controlled axes (X, Y, Z) and a robust steel frame. It serves as the core structure for integrating a wide range of modular welding extensions, including rotary tables, sliding systems, and powder feeders.

Key specifications:

• X-axis travel: up to 1,010 mm
• Y-axis travel: up to 1,110 mm
• Z-axis travel: up to 510 mm
• Modular expandability for different workpiece types and welding tasks

Benefits of the Simass Base Unit

• Modular Flexibility – Easily combine with Rotate, Slide, or Powder modules to adapt to complex production workflows.
• Precision Engineering – Achieve reliable welds with repeatable accuracy and minimal thermal distortion.
• Process Efficiency – Load and weld simultaneously with automated part handling, increasing throughput.
• Advanced Controls – Intuitive joystick and magnetic display with Sigomatic software integration.

Applications Across Industries

The Simass Base Unit is ideal for high-demand production environments such as:

• Aerospace & automotive – Precise welding of structural components
• Medical technology – Joining of surgical instruments and implants
• Toolmaking & repair – Automated hard-facing, buildup welding, and fine repairs
• Electronics & consumer goods – Micro-welding of complex assemblies
• Luxury & jewelry – Laser welding of precious metals and fine details

Enhance Your Welding Line with Simass Modules

• Simass Rotate: Enables dual-station welding with rotary table indexing for continuous operation.
• Simass Slide: Handles large, tubular, or oversized components with ease.
• Simass Powder: Supports additive welding processes with powder feeding capabilities.

Why Choose Sigma Laser’s Simass Base Unit?

With decades of experience in laser system engineering, Sigma Laser delivers state-of-the-art solutions tailored to your exact needs. Our Simass Base Unit offers the scalability and precision modern manufacturers demand — whether for high-volume production or specialized welding tasks.

Contact us today to discuss how the Simass system can optimize your production workflow.

📞 +49 (0) 6109 715 973-0
📧 info (at) sigma-laser.com

Comparison: Simass Base Unit vs. Competing Modular Laser Welding Systems

Feature	Simass Base Unit (Sigma Laser)	Typical Competing Systems
System Type	Modular, base platform with interchangeable extensions	Usually fixed-platform or semi-modular
Axis Configuration	3-axis CNC-controlled (X: 1010 mm, Y: 1110 mm, Z: 510 mm)	Varies: 2–3 axis; shorter travel ranges in entry-level models
Modular Expandability	✔ Rotate, Slide, Powder modules; plug-and-play integration	❌ Often limited or requires custom engineering
Cycle Efficiency	Simultaneous loading/unloading with rotary and slide modules	Loading often paused during welding; lower throughput
Control System	Joystick + Magnetic Display + Sigomatic software integration	Traditional touchscreen or industrial PC; less dynamic control
Ease of Use	Operator-friendly with programmable quick keys and memory	Complex interface requiring advanced training
Software Compatibility	Native Sigomatic support + real-time feedback + pulse memory	Often closed-loop systems with limited export/logging
Part Size Handling	Up to Ø500 mm / Length 1500 mm with Slide Module	Often limited to smaller parts unless fully custom
Target Industries	Aerospace, Toolmaking, Medical, Automotive, Jewelry	Primarily industrial fabrication; less adaptable across sectors
Maintenance & Serviceability	Modular design = easier part replacement & system upgrades	Maintenance may require OEM-specific support
Cost Efficiency	High ROI through modular scaling + reduced custom design	Higher initial cost for custom solutions or large formats

Key Advantages of Simass Base Unit:

• Scalability: One core unit, multiple optional modules — lower cost for future expansions.
• Customization without Complexity: Off-the-shelf modular upgrades, no need for full redesign.
• Industry-Specific Adaptability: Built for tooling, surgical components, electronics, and even precious metal work.
• Real-Time Control: Advanced control software with intuitive operator tools and data logging.

When to Choose Simass Base Unit:

• You require modular adaptability without the need for custom-built machinery.
• Your workflow benefits from simultaneous load-weld cycles.
• You need to weld various part sizes and shapes across multiple product lines.
• You want rapid deployment without extended design or commissioning cycles.

Sigomatic Software Integration with the Simass Base Unit

The Simass Base Unit is fully integrated with Sigomatic, Sigma Laser’s proprietary laser control software. This advanced platform enables intuitive operation, precise control of welding parameters, and full automation of complex welding tasks — making it ideal for high-precision, high-throughput production environments.

What Is Sigomatic?

Sigomatic is a dedicated laser process management software developed by Sigma Laser. It offers real-time control, programmable sequences, and automated path management for laser welding operations. It acts as the central intelligence behind the Simass system, synchronizing movement, pulse timing, and auxiliary device operations.

Key Features of Sigomatic with Simass

Feature	Description
Path Control	Full control of motion paths for all CNC axes (X, Y, Z + optional 4th axis)
Pulse Synchronization	Automatic timing of laser pulses with axis movement and part rotation
Data Logging	Recording of pulse counts, operating hours, weld sequences, and operator inputs
Program Memory	Up to 50 memory slots for repeatable welding programs and parameter profiles
Real-Time Feedback	Live display of process parameters, including power, speed, and focus position
Touch Interface / Joystick	Multi-function joystick with digital/analog control and magnetic touch display
Multi-Zone Automation	Supports dual-station setups (e.g., Rotate module) for load/weld synchronization
Quick Swap Parameters	Programmable hotkeys for instant access to pre-set configurations
Modular Compatibility	Seamlessly integrates with Simass Rotate, Slide, and Powder modules

Benefits of Sigomatic Integration

• Minimized Setup Time – Quickly load saved jobs and parameters for repeat tasks
• Increased Productivity – Real-time error detection, process monitoring, and optimization
• Improved Quality Assurance – Process consistency with programmable and repeatable welds
• Scalable for Industry 4.0 – Data output can be linked with MES/SCADA systems for full traceability

Application Use Cases

• Tool & mold repair: Set specific laser paths and automate pulsed weld patterns
• Medical device manufacturing: Ensure traceability and quality control via logged parameters
• Rotational part welding: Coordinate laser pulses with rotary motion for precise seam welding
• High-mix production: Quickly switch between jobs using saved program profiles

User Interface & Accessibility

Operators interact with Sigomatic through a magnetically mounted display on the Simass Base Unit, offering:

• Intuitive navigation
• Programmable control shortcuts
• Diagnostics and maintenance logs
• USB/Ethernet interface for backup and software updates

Conclusion

The Sigomatic software platform transforms the Simass Base Unit into a smart laser welding workstation, streamlining setup, improving precision, and enabling digital manufacturing integration. Whether you’re producing medical implants, automotive components, or tooling parts, Sigomatic ensures your processes are controlled, traceable, and future-ready.

Simass Base Unit — Operator Quick Guide & FAQ

This guide helps you get started with basic operation and answers common questions.

Getting Started

1. How do I turn on the machine?

• Switch on the main power supply at the control panel.
• Press the green Start button on the joystick/display unit.
• Wait for the system to initialize and display the home screen.

2. How do I load a welding program?

• Use the magnetic display touch screen.
• Select Program Memory and choose from up to 50 saved jobs.
• Confirm selection; the program parameters will load automatically.

3. How do I move the welding head?

• Use the joystick to manually move the laser head along X, Y, and Z axes.
• Press the Vmax button for faster movements.
• Use the joystick’s programmable buttons for quick axis changes.

4. How do I start the welding process?

• Ensure your workpiece is correctly positioned and secured.
• Select the welding program.
• Press the Start Welding button on the display or joystick.
• Monitor the process on the screen; emergency stop is available anytime.

Common Questions (FAQ)

Q: What if the laser doesn’t fire?

• Check that the laser source is powered on.
• Ensure safety interlocks (doors, shields) are closed.
• Verify the welding program parameters include pulse activation.
• Contact maintenance if the problem persists.

Q: Can I pause or stop the welding mid-process?

• Yes, press the Pause button on the joystick/display to temporarily halt welding.
• Press Stop to terminate the cycle completely.

Q: How do I change the welding parameters?

• Access Settings on the magnetic display.
• Adjust power, pulse frequency, speed, or focus position as needed.
• Save changes to a new program slot for future use.

Q: How do I perform routine maintenance?

• Clean optics and lenses daily to prevent dust buildup.
• Check mechanical components for wear weekly.
• Follow the manufacturer’s maintenance checklist in the manual.

Q: How can I save and backup welding programs?

• Use the USB port on the display unit to export program data.
• Store backups on an external device for safety.

Q: What safety precautions should I observe?

• Always wear appropriate laser safety goggles.
• Keep the work area free of reflective materials.
• Never bypass safety interlocks or shields.
• Follow emergency procedures for fire or laser malfunction.

Tips for Efficient Operation

• Use program memory slots to quickly recall common jobs.
• Regularly update your welding programs with optimized parameters.
• Keep the joystick and display clean for reliable operation.
• Report any unusual noises or errors immediately.

SIMASS ROTATE (Custom Laser Welding System)

SIMASS ROTATE is a specialized custom laser welding system developed by Sigma Laser GmbH. It belongs to the broader category of custom special machines, with a focus on automated laser-based joining processes for rotationally symmetrical components. The system is part of Sigma Laser’s SIMASS (Sigma Modular Automation System Solutions) product family, designed for high-precision, high-speed welding in industrial manufacturing environments.

Overview

The SIMASS ROTATE system is engineered to perform fully automated laser welding tasks on components that require rotational manipulation during the welding process. It is typically used for parts with circular or cylindrical geometries, such as gear components, sensor housings, shaft assemblies, and bearing rings.

The system integrates a rotary indexing table, multi-axis motion control, and high-power fiber lasers to enable 360-degree welds with precise seam tracking and consistent quality. It is designed for both standalone operation and integration into larger production lines.

Technical Features

Key components and capabilities of the SIMASS ROTATE system include:

• Rotary Table System: A robust, motor-driven rotary axis that positions the workpiece for precise circumferential welding. Indexing or continuous rotation modes are supported depending on the weld geometry.
• Laser Welding Module: Typically includes a fiber laser (e.g., IPG or similar), beam delivery optics, and focusing units with adjustable focal lengths for various material thicknesses and welding depths.
• Modular Workstation Design: The system is built on a modular platform, allowing easy customization based on part size, laser power, number of stations, and automation needs.
• Integrated Clamping Fixtures: Customizable fixturing and clamping tools ensure accurate positioning and secure holding of each part during the welding process.
• Camera and Monitoring Systems: Optional integration of seam tracking cameras, vision inspection, and quality control units for real-time feedback and process validation.
• CNC or PLC Control: Advanced software and control electronics allow programming of weld paths, laser parameters, rotational speeds, and cycle times.
• Safety Enclosure: Enclosed laser-safe cabin with interlocks and fume extraction for operator protection and compliance with laser safety standards (Class 1 system).

Applications

SIMASS ROTATE is designed for industries that require rotational symmetry in weld paths or benefit from rotary automation. Typical applications include:

• Automotive sector: Welding of ring gears, pressure plates, and clutch assemblies.
• Sensor and electronics enclosures: Laser welding of sealed sensor bodies with circular sealing seams.
• Mechanical engineering: Joining of flanges, bearing races, and cylindrical housings.
• Medical devices: High-precision welding of circular titanium or stainless-steel components.

Advantages

The SIMASS ROTATE system provides multiple benefits to industrial users:

• High precision and repeatability for circumferential welds.
• Reduced cycle times due to automation and multi-station design.
• Minimized heat input and distortion through controlled laser parameters.
• Custom configuration for different workpiece sizes and production volumes.
• Seamless integration with upstream and downstream handling systems.

Manufacturer and Development

SIMASS ROTATE is developed and manufactured by Sigma Laser GmbH, a German technology company specializing in advanced laser processing solutions. The SIMASS platform reflects the company’s commitment to modular, scalable, and application-specific automation systems tailored to customer needs.

Related Systems

The SIMASS ROTATE is part of a family of custom machines under the SIMASS brand, which also includes systems for:

• Laser marking
• Laser engraving
• Laser cleaning
• Other rotary or linear processing tasks

Each system is configurable with different laser sources, motion systems, and safety enclosures to meet specific production demands.

SIMASS ROTATE – Precision Laser Welding for Rotational Parts :: customer object handling section

SIMASS ROTATE is a fully automated rotary laser welding system engineered by Sigma Laser GmbH. Purpose-built for high-precision welding of rotationally symmetrical components, this system ensures maximum productivity, quality, and flexibility across demanding industrial applications.

Whether you’re welding gear rings, cylindrical housings, or sensor components, SIMASS ROTATE delivers unmatched accuracy and repeatability with every cycle.

Engineered for Rotational Laser Welding Excellence

At the heart of SIMASS ROTATE is a robust rotary indexing table combined with high-performance fiber laser technology. This configuration enables 360° continuous or indexed laser welding, ideal for parts with circular weld seams or rotating geometries.

Core Features:

• Rotary Table Integration: Precision-controlled rotation for symmetrical welds.
• Modular Design: Custom-built based on your part sizes, materials, and process flow.
• Advanced Laser Control: Seam tracking, pulse shaping, and laser power optimization.
• Automation-Ready: Easily integrates into your production line or operates as a standalone workstation.
• Safety First: Class 1 laser enclosure with fume extraction and operator interlocks.

Applications of SIMASS ROTATE

SIMASS ROTATE is optimized for industries that require circular or rotational welding precision:

• Automotive: Ring gears, clutch components, flywheel assemblies
• Aerospace: Structural rings, sealed housings, sensor bodies
• Medical Devices: Precision enclosures for implants and surgical instruments
• Electronics: Sealed enclosures and rotary sensor units
• Mechanical Engineering: Shafts, flanges, and cylindrical tooling parts

Benefits of SIMASS ROTATE for Your Production

• Precision and Repeatability – Consistent weld quality across every unit
• Time and Cost Efficiency – Fast cycle times reduce production costs
• Custom-Fit Automation – Scalable solution tailored to your specific workflow
• Reduced Downtime – Seamless part handling, quick setup, and minimal maintenance
• Superior Weld Integrity – Minimal distortion, excellent joint strength, and clean seams

Tailored to Your Process – The SIMASS Platform

SIMASS ROTATE is part of the SIMASS (Sigma Modular Automation System Solutions) series — a family of flexible, scalable systems designed for laser welding, laser marking, cleaning, and engraving applications. Each system can be configured with custom:

• Laser sources (e.g., fiber lasers with adjustable power)
• Motion systems (rotary, linear, robotic)
• Clamping fixtures and handling units
• Quality control and vision systems

Why Choose Sigma Laser?

With over a decade of experience in industrial laser systems, Sigma Laser GmbH offers:

• German-engineered reliability and innovation
• End-to-end project support: from concept to installation
• Global service and technical assistance
• Proven results across automotive, aerospace, and medical sectors

Get a Custom Quote Today

Looking for a custom laser welding machine for rotational parts?
Contact Sigma Laser today to configure your SIMASS ROTATE system for your production needs.

📞 +49 (0) 6109 715 973-0
📧 info (at) sigma-laser.com

SIMASS ROTATE vs. Competing Rotary Laser Welding Systems

Feature	SIMASS ROTATE (Sigma Laser GmbH)	Trumpf TruLaser Station 7000	IPG LightWELD Workstations	AMADA ENSIS Rotary Welding Cell
Primary Focus	Custom rotary laser welding of symmetrical components	High-performance micro and macro laser welding	Compact fiber laser welding (manual & semi-auto)	Rotary laser cell for mass production
Modularity	✔ Highly modular – tailored to each client	✖ Fixed configurations, limited to catalog specs	✔ Semi-modular, but limited automation	✖ Limited – primarily for large-volume configurations
Rotary Axis System	✔ Integrated rotary table with programmable indexing or continuous motion	✔ Precision rotation with optional automation	✖ Manual fixturing or low-level rotation	✔ Integrated rotary table, mostly for fixed part formats
Automation & Integration	✔ Fully integrable with robotic arms, conveyors, MES systems	✔ Partial integration with automation add-ons	✖ Limited automation, mostly standalone	✔ Pre-integrated automation for high throughput
Laser Source Options	✔ Full range of fiber lasers from 150W–6kW (e.g., IPG, SPI)	✔ Trumpf fiber and disk lasers	✖ IPG low to mid-range power only (max ~1500W)	✔ ENSIS fiber lasers with proprietary beam shaping
Customization Level	🟢 High – Fully custom (motion, fixturing, laser, UI)	🔴 Low – Limited to factory options	🟡 Medium – Manual customization only	🔴 Low – Mass-market product line
Industries Served	Automotive, aerospace, medical, electronics, tooling	Medical, aerospace, electronics	Electronics, medical, general manufacturing	Automotive, appliance, heavy industry
User Interface / Control	✔ Custom UI (Siemens/Beckhoff/PLC) + CNC with custom HMI	✔ Trumpf proprietary control	✖ Basic control panel	✔ AMADA control suite
Footprint & Space Efficiency	🟢 Compact, custom-fitted to facility size	🔴 Large footprint, standardized cell	🟢 Compact bench-top and workstation options	🔴 Large and fixed footprint
After-Sales Support	🟢 Direct engineering support + German-made components	🟢 Global support network	🟢 Extensive IPG network	🟢 Global, with strong Japan/EU base
Best For	Manufacturers needing tailor-made rotary laser systems	Precision welds in medical or aerospace	Entry-level or low-budget fiber welding	High-volume automotive manufacturers
Weakness	Requires engineering lead time	Limited flexibility; higher cost	Not suitable for full automation	Expensive, low customization

Key Differentiators of SIMASS ROTATE:

• ✅ High Customization: Unlike standard machines, SIMASS ROTATE is designed around your part and process.
• ✅ True 360° Rotary Welding: Offers both indexed and continuous rotation, essential for cylindrical or ring welds.
• ✅ Scalable Modularity: Add robotics, vision systems, or MES connectivity as your process evolves.
• ✅ Compact & Flexible: Efficient design allows for space savings without compromising performance.
• ✅ Vendor-Neutral Laser Sources: Compatible with IPG, SPI, or custom beam sources — you’re not locked into one brand.

When to Choose SIMASS ROTATE:

Choose SIMASS ROTATE if:

• You need a rotary welding solution customized for your parts, not a one-size-fits-all machine.
• You want to integrate laser welding into your automation ecosystem.
• Your parts require circular or radial welds with exact alignment and speed.
• Your process demands German engineering quality with personalized technical support.

Sigomatic Software Integration in SIMASS ROTATE

Sigomatic is the proprietary automation and control software platform developed by Sigma Laser GmbH. It is used across the SIMASS product family, including the SIMASS ROTATE system, to manage laser processes, motion control, automation sequences, and system diagnostics. Sigomatic provides a unified interface that enables users to configure, monitor, and optimize their custom laser welding workflows with precision and repeatability.

Overview

Sigomatic acts as the central control environment for SIMASS ROTATE, facilitating seamless coordination between:

• Laser source control
• Rotary axis movement
• Part positioning and clamping
• Weld sequence execution
• Sensor feedback and process monitoring
• Safety and interlock management
• User interface (HMI) interaction

The software is typically deployed on an industrial PC (IPC) and communicates via real-time protocols (e.g., EtherCAT, Profinet, or Modbus) with all peripherals.

Key Features

1. User-Friendly HMI (Human-Machine Interface)

• Customizable UI dashboards based on user roles (operator, technician, admin)
• Touchscreen support and intuitive menu navigation
• Real-time weld status, fault messages, and cycle time data

2. Motion Control Integration

• Supports multi-axis motion systems, including rotary tables and linear stages
• Full coordination of rotational speed, dwell times, and laser firing points
• Parametric programming for different part geometries

3. Laser Control Interface

• Integration with leading fiber laser brands (IPG, SPI, Trumpf, etc.)
• Control of laser power, frequency, pulse duration, and spot size
• Live adjustment or pre-programmed pulse shaping

4. Recipe & Process Management

• Store and recall unlimited welding recipes and part programs
• Version control and part traceability
• Barcode/RFID integration for automatic recipe selection

5. Vision & Quality Modules (Optional)

• Integration of camera-based seam tracking or vision inspection
• Real-time data logging and quality feedback
• Weld pass/fail signal output to MES or SCADA systems

6. MES / ERP Integration

• OPC UA, MQTT, or RESTful API support for factory connectivity
• Export of production data, cycle counts, error logs, and analytics
• Machine status monitoring and predictive maintenance interfaces

7. Safety & Diagnostics

• Status of interlocks, enclosure doors, fume extraction, and emergency stops
• Fault code history and automatic fault escalation
• Guided maintenance and service reminders

Compatibility and Extensibility

• Works with Beckhoff, Siemens, and B&R control platforms
• Easily extendable with custom modules for industry-specific features
• Multilingual support for global deployment (e.g., English, German, Farsi)
• Designed for Industry 4.0 environments and smart factory systems

Benefits of Sigomatic Integration in SIMASS ROTATE

✅ End-to-End Control: One system handles all aspects of welding, motion, and part handling
✅ Faster Setup: Intuitive interface and recipe library speed up changeovers
✅ High Precision: Coordinated motion and laser control deliver superior weld quality
✅ Data-Driven Insights: Log every weld cycle for QA and traceability
✅ Future-Ready: Open interfaces for MES, vision, robotics, and cloud systems

Sample Use Case: SIMASS ROTATE with Sigomatic

In a production line welding automotive ring gears, Sigomatic manages:

• Automated clamping via pneumatics
• Indexing the rotary table to each weld start point
• Triggering the fiber laser with predefined parameters
• Capturing seam inspection data
• Logging results and sending pass/fail status to the MES

SIMASS ROTATE — Operator Quick Guide & FAQ

Welcome to SIMASS ROTATE

This system uses laser welding to join rotating parts precisely and automatically. The Sigomatic software controls all machine functions.

Basic Operation Steps

1. Power On

• Turn on the main power switch.
• Start the control PC and Sigomatic software.
• Wait for the system status to show Ready.

2. Loading Parts

• Open the safety enclosure door (if manual loading).
• Place the workpiece securely in the fixture/clamp.
• Close the safety door fully — the machine will check interlocks.

3. Select Program

• Use the touchscreen to select the welding recipe matching your part.
• Confirm parameters if needed (usually pre-set).

4. Start Welding

• Press the Start button on the HMI.
• The rotary table will index or rotate continuously.
• Laser welding begins automatically according to the program.

5. Monitoring

• Watch the welding progress on screen.
• The system displays weld status and any warnings/errors.
• Do not open the enclosure during operation.

6. Unloading Parts

• After welding completes and the system indicates Cycle End, open the safety door.
• Remove the finished part carefully.
• Load the next part or shut down if finished.

Common Operator FAQ

Q1: What if the machine shows an error?

A: Read the error message on screen. Common errors: safety door open, fixture not detected, or laser fault. Follow the on-screen instructions to resolve or notify maintenance.

Q2: Can I adjust the welding parameters?

A: Operators usually run pre-set programs. Do not change parameters unless authorized and trained.

Q3: How do I select the correct welding program?

A: Programs are named or coded by part type. Confirm with your supervisor or production plan which to select.

Q4: What safety precautions should I follow?

A: Always ensure the enclosure door is closed before starting. Wear protective eyewear if instructed. Do not bypass safety interlocks.

Q5: How do I know the weld quality?

A: The system may include a vision or sensor check with a pass/fail indication. For detailed quality control, follow your plant’s inspection procedures.

Q6: What if the rotary table doesn’t rotate?

A: Check for error messages. Ensure parts are clamped properly and no mechanical jams exist. If unresolved, contact maintenance.

Q7: Can I stop the welding cycle mid-way?

A: Use the Emergency Stop button for immediate stop in emergencies only. Normal stop requires completing or aborting the program via the HMI.

Q8: What routine maintenance should I perform?

A: Clean the fixture and work area daily. Report any unusual noises or malfunctions. Follow maintenance schedules for laser optics and filters.

Tips for Smooth Operation

• Always verify parts before loading (correct type, no damage).
• Keep the workspace clean and free from dust or debris.
• Report any irregularities immediately to supervisors.
• Attend regular training refreshers on Sigomatic use.

SIMASS SLIDE – Custom Laser Welding System by Sigma Laser

SIMASS SLIDE is a specialized custom laser welding system developed by Sigma Laser GmbH, designed for high-precision welding applications requiring reliable automation and flexible handling of complex components. It is part of the company’s portfolio of custom special machines, engineered to provide tailored solutions for demanding industrial welding tasks.

Overview

The SIMASS SLIDE system is a modular laser welding machine that combines advanced laser technology with automated handling and precision positioning. It is particularly suited for medium to high volume production environments where reproducibility, flexibility, and process quality are critical.

Designed to be adaptable, the SIMASS SLIDE supports a wide range of welding applications across different materials and product sizes, offering a compact footprint while maintaining high throughput and weld accuracy.

Technical Features

• Laser Source: The system typically uses high-quality fiber laser sources, enabling efficient energy delivery and deep penetration welding with minimal thermal impact.
• Workpiece Handling: Equipped with a motorized linear slide (hence the name “SLIDE”), it allows precise, programmable positioning of the part relative to the laser beam, facilitating complex weld paths.
• Automation: The machine integrates optional robotic arms or custom part feeders to automate loading/unloading and reduce manual intervention.
• Control System: CNC or PLC-based controls provide flexible programming of welding parameters, motion sequences, and safety interlocks.
• User Interface: Intuitive software allows operators to quickly set up new welding programs and monitor process variables in real time.
• Safety Features: Enclosed laser safety housing and sensors ensure compliance with laser safety regulations and protect operators.

Applications

The SIMASS SLIDE system is designed for industries that require precision welding of components with challenging geometries or tight tolerances, including:

• Automotive parts such as brackets, housings, and battery components.
• Medical device manufacturing where precise, contamination-free welds are essential.
• Electronics industry for welding small, sensitive components.
• Toolmaking and small machinery for joining high-quality tooling components.
• Other specialized manufacturing processes requiring tailored laser welding solutions.

Advantages

• Precision and Repeatability: The motorized slide enables exact positioning for consistent weld quality.
• Flexibility: Modular design supports quick adaptation for different parts or production changes.
• Compact Design: Optimizes factory floor space while maintaining throughput.
• Ease of Integration: Can be combined with other automation modules or incorporated into existing production lines.
• Improved Process Efficiency: Reduces cycle time and operator workload through automation.

Manufacturer Background

Sigma Laser GmbH, headquartered in Germany, specializes in laser technology solutions including fiber laser sources and custom laser machines. The SIMASS SLIDE exemplifies their approach to delivering customer-specific machinery tailored for optimized laser welding performance.

SIMASS SLIDE – Custom Laser Welding System by Sigma Laser :: customer object handling section

Precision Laser Welding with Advanced Automation

The SIMASS SLIDE from Sigma Laser is a cutting-edge custom laser welding system designed to deliver unparalleled precision, flexibility, and efficiency for your industrial welding needs. Engineered with a motorized linear slide for exact part positioning, SIMASS SLIDE offers a perfect combination of high-quality fiber laser technology and automated handling to optimize your production workflow.

Key Features of SIMASS SLIDE

• Customizable laser welding solutions tailored to your specific part geometry and production volume.
• High-precision motorized slide system enabling consistent, repeatable welds on complex components.
• Advanced fiber laser sources for fast, deep penetration welding with minimal heat impact.
• Flexible automation options including robotic loaders and part feeders to minimize manual labor.
• User-friendly CNC controls with easy programming and real-time process monitoring.
• Compact and modular design suitable for integration into existing production lines.
• Safety compliance with fully enclosed laser housings and interlocks.

Industries & Applications

The SIMASS SLIDE laser welding machine is ideal for a broad range of industries requiring exacting weld quality, including:

• Automotive manufacturing: battery components, brackets, housings
• Medical devices: sterile, precise welds for surgical tools and implants
• Electronics: welding of small, sensitive parts with minimal distortion
• Aerospace and defense: lightweight alloy joining with high repeatability
• Tooling and machinery: complex component fabrication with tight tolerances

Why Choose SIMASS SLIDE?

By choosing the SIMASS SLIDE custom laser welding system, your business benefits from:

• Improved welding accuracy and product quality
• Increased production speed and throughput
• Reduced waste and rework thanks to precise laser control
• Lower operational costs through automation and reduced manual intervention
• Scalability to adapt to new product lines or design changes

Learn More About SIMASS SLIDE

Ready to upgrade your laser welding capabilities? Contact Sigma Laser today to discuss how the SIMASS SLIDE custom laser welding system can be tailored to your manufacturing needs. Benefit from expert consultation, turnkey installation, and comprehensive after-sales support.

SIMASS SLIDE vs. Competing Custom Laser Welding Systems

When choosing a custom laser welding system, it’s essential to compare key features that impact precision, flexibility, and efficiency. Here’s how SIMASS SLIDE by Sigma Laser stands out against other available laser welding solutions:

Feature	SIMASS SLIDE (Sigma Laser)	Typical Competitors
Positioning System	Motorized linear slide for precise, programmable movement	Often fixed or manually adjusted stages, less flexible
Laser Source	High-quality fiber laser with deep penetration and high efficiency	Some use older solid-state or CO2 lasers with lower efficiency
Automation Integration	Easily integrates robotic loaders, conveyors, and feeders	May require costly add-ons or lack modular automation
Control Interface	User-friendly CNC/PLC with real-time monitoring and easy programming	Often less intuitive software, limited monitoring tools
Machine Footprint	Compact, modular design optimized for factory floor space	Bulkier systems requiring more space
Safety Features	Fully enclosed laser housing with interlocks and sensors	Varies widely; some lack comprehensive safety enclosures
Customization & Flexibility	Designed and built to client specifications for various part sizes and materials	Limited customization, often built for standard part geometries
After-Sales Support	Comprehensive service, training, and technical support worldwide	Support quality varies, sometimes limited by region

Why SIMASS SLIDE Leads the Market

• Precision Positioning: The motorized slide allows fine, repeatable adjustments unmatched by competitors, improving weld quality.
• Energy-Efficient Fiber Lasers: Sigma Laser uses modern fiber lasers that reduce operating costs and increase welding speed.
• Plug-and-Play Automation: Ready integration with automation solutions reduces production downtime and operator workload.
• User-Centric Controls: Intuitive software accelerates setup times and minimizes programming errors.
• Tailored Solutions: SIMASS SLIDE machines are customized to meet specific customer needs, ensuring optimal process fit.
• Dedicated Support: Sigma Laser offers ongoing training and fast service response, critical for minimizing production interruptions.

Integration of Sigomatic Software with SIMASS SLIDE Laser Welding System

Sigomatic is Sigma Laser’s proprietary software platform designed to provide seamless control, monitoring, and automation of custom laser welding systems such as the SIMASS SLIDE. Its integration enables enhanced process precision, operational efficiency, and data-driven quality control.

Key Integration Features

• Centralized Control Interface:
  Sigomatic serves as a unified control panel for managing laser parameters, motion control (including the motorized slide), and peripheral devices (robotic arms, conveyors, sensors). Operators can easily configure welding programs, adjust process variables, and initiate jobs from a single dashboard.
• Real-Time Process Monitoring and Visualization:
  The software continuously monitors key welding parameters (laser power, speed, position, temperature, etc.) and provides live visual feedback, including 2D/3D graphical representations of the welding path. This real-time insight helps detect anomalies and maintain consistent weld quality.
• Programmable Welding Sequences:
  Sigomatic supports flexible programming of welding sequences using an intuitive graphical interface or scripting environment. This allows for customized weld paths, multiple passes, and conditional process steps tailored to complex part geometries.
• Automation and Robotics Integration:
  The platform can communicate bidirectionally with robotic controllers and peripheral automation devices through industry-standard protocols (e.g., OPC UA, Ethernet/IP, Profinet). This ensures smooth synchronization between welding and part handling operations, reducing cycle times and manual intervention.
• Data Logging and Quality Traceability:
  Sigomatic records detailed process data and weld logs for each production cycle. These records facilitate quality assurance, traceability, and compliance with industry standards. Data can be exported for offline analysis or integrated with factory MES/ERP systems.
• Remote Access and Diagnostics:
  The software supports remote connectivity for troubleshooting, software updates, and performance diagnostics. Maintenance teams can quickly identify and resolve issues, minimizing downtime.

Integration Benefits for SIMASS SLIDE Users

• Streamlined operation via an all-in-one control system
• Increased weld accuracy through precise parameter adjustments
• Enhanced production efficiency with synchronized automation
• Improved quality control backed by comprehensive data logging
• Reduced maintenance time thanks to proactive diagnostics

SIMASS SLIDE

Operator User Guide & FAQ

Quick Start Guide

1. Power On

• Ensure the main power switch is ON.
• Start the control panel and wait for the system to initialize.

2. Loading the Workpiece

• Open the safety enclosure door (if applicable).
• Place the workpiece securely on the fixture or slide table.
• Close the safety door to enable laser operation.

3. Selecting the Program

• On the touchscreen/control panel, choose the appropriate welding program for your part.
• Verify welding parameters if necessary (laser power, speed, position).

4. Start Welding

• Press the Start button to begin the welding process.
• Monitor the process via the control screen for any alerts or errors.

5. Unloading the Workpiece

• When welding completes, wait for the laser and motion to stop.
• Open the safety door and carefully remove the welded part.
• Prepare for the next cycle.

6. Power Off

• After the last workpiece is done, shut down the system via the control panel.
• Turn off the main power switch if no further operation is planned.

Safety Tips

• Always keep safety doors closed during operation to prevent laser exposure.
• Wear appropriate personal protective equipment (PPE) if required.
• Do not attempt to override safety interlocks.
• Report any abnormal sounds, smells, or errors immediately.

Frequently Asked Questions (FAQ)

Q1: How do I select the right welding program?

A: Use the part ID or batch number to find the corresponding program on the control panel. Programs are saved and named according to part specifications.

Q2: What should I do if the machine displays an error?

A: Refer to the error code on the screen and check the operator manual for troubleshooting steps. If unresolved, notify the maintenance team.

Q3: Can I adjust welding parameters manually?

A: Yes, but only if authorized and trained. Incorrect settings can cause poor weld quality or damage.

Q4: How do I maintain the machine daily?

A: Keep the work area clean, remove dust and debris, inspect fixtures for wear, and ensure the laser optics window is clean. Report any signs of wear or malfunction.

Q5: What materials can be welded on SIMASS SLIDE?

A: Common materials include stainless steel, aluminum, and other metals compatible with laser welding. Confirm with your supervisor if unsure.

Q6: How do I handle a workpiece jam or misalignment?

A: Stop the machine immediately. Open the safety door and carefully remove the part. Check fixtures and alignment before restarting.

Q7: What is the recommended shift procedure for multiple operators?

A: Each operator should log out/in on the control system and communicate any issues during handover. Follow your facility’s standard operating procedures.

Comparison: Simass Base Unit vs. Simass Rotate vs. Simass Slide :: buyer guide

Here is a detailed comparison between the three core systems within Sigma Laser’s Custom Special Machines category:

• Simass Base Unit
• Simass Rotate
• Simass Slide

This table and summary help clarify the differences in design, use cases, and capabilities for operators, buyers, or decision-makers.

Feature / System	Simass Base Unit	Simass Rotate	Simass Slide
Type	Core modular platform for laser welding	Rotary extension for dual-station welding	Slide-based extension for long/tubular parts
Axis Travel (X / Y / Z)	X: 1010 mmY: 1110 mmZ: 510 mm	Same as Base Unit	Same as Base Unit
Rotation Capability	❌ No built-in rotation	✔ Rotary table (Ø up to 1500 mm)	❌ Not included
Simultaneous Load/Weld	❌ Not supported	✔ Yes — one station welds while other is loaded	✔ Yes — one station welds while other slides out
Ideal for	General-purpose setups; adaptable with modules	High-speed production lines with part cycling	Large, tubular, or long-format parts (e.g. shafts, cylinders)
Typical Parts	Standard 3D workpieces	Fixtures, dies, flat parts, housings	Pipes, molds, tools, long components
Automation Level	Moderate; add-on ready	High — rotary automation built-in	High — fully motorized slide control
Footprint / Size	Compact (base frame only)	Larger (rotary table included)	Extended footprint (slide rails + part holder)
Handling Method	Manual or integrated robot possible	Operator or robot at loading station	Auto-sliding table with motorized positioning
Modules Compatibility	Base for all modular systems (Rotate, Slide, Powder, etc.)	Extension module built onto base unit	Extension module built onto base unit
Best Use Case	Custom low- to mid-volume laser welding setups	Fast-paced production requiring cycle optimization	Precision welding of oversized or tubular parts

Summary of Each System

Simass Base Unit

• The foundational platform.
• Supports precision 3-axis motion and is fully modular.
• Perfect for customizing with your choice of extensions like Rotate or Slide.

Use it when: You need flexibility and plan to build a custom workflow using various modules.

Simass Rotate

• Adds a motorized rotary table to the base unit.
• Enables simultaneous part loading and welding, boosting throughput.
• Two stations rotate in and out for continuous processing.

Use it when: You’re working in a high-volume environment where speed and cycle time matter (e.g., automotive, tooling).

Simass Slide

• Adds a sliding worktable system ideal for large, long, or cylindrical parts.
• Enables welding in one zone while preparing in another.
• Supports vertical and horizontal welding.

Use it when: You handle oversized or tubular parts and need high precision and mobility in loading.

Which One Should You Choose?

Need	Recommended System
Flexibility & future upgrades	Simass Base Unit
Fast production with minimal downtime	Simass Rotate
Welding large, heavy, or tubular pieces	Simass Slide