Manual Welding Positioner - Repeatable Results

Challenges

When marrying a manifold to a precision pump assembly, even small inconsistencies can cause major setbacks. Specifically, for this manufacturer, the risk of misalignment increased every time the part was removed from the fixture for repositioning or transferred from tacking to welding. Additionally, weld distortion tended to pull the outer tubes inward, compromising part quality.

Ultimately, their previous fixturing setup wasn’t up to the task. It lacked the control and repeatability they needed, especially without a manual welding positioner to keep the work stable and accessible throughout the process.

Solution

• Manual positioner

• Adjustable picture frame

• Modular components on each tube end

To address this, Bluco engineers delivered a modular solution that checked all the boxes. At its core was a manual welding positioner, which allowed the part to be rotated for better access—without the need to remove or reposition it on a table. As a result, welders could now reach every joint with minimal effort, increasing consistency across the board.

Additionally, adjustable picture frame fixturing accommodated different product sizes, while modular end components held the manifold firmly at key points. Clamps and spacers allowed for fine-tuning—down to 1mm adjustments on the outer tubes—to counter weld draw.

Thanks to its design, this fixture’s modularity also means it can adapt to future design changes or part revisions, making it a long-term asset.

Result

The result? Better welds in less time.

Now, with the manual welding positioner and modular fixture working together, welders can tack and complete welds in a single setup. There’s no longer a need to reposition parts mid-process. Thus, eliminating a major source of inconsistency. Because the system locks all three tubes firmly in place while still allowing small adjustments, controlling weld draw is simple and repeatable.

In the end, this has led to improved fit-up with the pump assembly, better final part quality, and greater confidence in achieving consistent, repeatable results.