Modular Fixturing for Welding - Frames at Any Size

Challenges

When welding window and door frames with finished sizes ranging from 12 inches to 12 feet square, every measurement and angle must be exact. In this case, the manufacturer’s previous setup wasn’t up to the task. It couldn’t support the full range of frame sizes, and its lack of precision led to alignment issues.

On top of that, the workstation design made it uncomfortable and inefficient for welders. In some cases, they even had to climb onto the table to reach their welds! This was both a safety concern and a productivity bottleneck.

The manufacturer needed a solution that would work today while also supporting their long-term plans. Specifically, they needed a fixture that could integrate with robotic welding down the line. That’s where modular fixturing for welding became the best path forward.

Solution

• U-form picture frame

• Adjustable width

• CAD templates

To address the challenge, Bluco developed a solution that featured a U-form picture frame with an open center and a rolling side. This welding fixture design accommodates a wide range of frame sizes and gives welders easy access to all corners. In addition, anchored feet provide a solid, reliable base.

Meanwhile, CAD templates ensure quick and accurate changeover from part to part. The flexibility and precision of modular fixturing for Welding allow the fixture to adapt as needed—without compromising accuracy.

Result

Now, frames of all sizes come together smoothly and efficiently. Length, width, and corner-to-corner dimensions are consistent between parts, thanks to precise tooling setup directly from CAD model templates.

Furthermore, the fixture now takes up less floor space than the original 12-foot table, while dramatically improving weld access and changeover speed.

And finally, the modular system is compatible with robotic welding, so the shop can scale up to automation seamlessly — without replacing their fixturing solution. By choosing modular fixturing for welding, this manufacturer solved their immediate challenges, and prepared themselves for future growth.