Multi-Integrator of cutting technology
and production automation

The offshore and onshore energy sectors work on higher strength materials, in thicknesses up to 300 mm and in environments where every hour of downtime means millions of dollars in losses. Absolute process reliability, equipment resistance to salt spray, moisture and dust, and the ability to machine higher-impact steels without losing edge quality are therefore crucial. Workpieces must come out of preparation with X, Y or K phases with perfect geometry to reduce the time for multi-layer welding and minimize the risk of RT/UT inconsistencies.

DNV, NORSOK and EN 1090-EXC4 standards, on the other hand, dictate full traceability, automatic archiving of cutting parameters and the ability to generate a QA report at the inspector’s request. Due to project locations – from offshore wind farms to FPSO modules – production lines must be modular, easily relocatable and suitable for 24/7 operation. STIGAL provides solutions designed precisely for these extreme conditions, combining performance with operator safety and compliance with strict industry standards.

The shipyards operate in project mode, where the hull block schedule is synchronized hourly with cranes and construction section lines. The number one need is high throughput cutting of sheathing panels and long sections while maintaining tolerances of ±0.5 mm on lengths over 20 m. Any inaccuracy results in costly undercutting and adjustments during block fusion, and any excessive weld gap generates additional pounds of welding material and straightening distortion.

The industry therefore requires processes that simultaneously cut the contour, prepare the chamfer and mark assembly references to reduce section fit times. In overhaul, on the other hand, flexibility is a priority: the ability to quickly process unique parts, often from dirty or corroded steel. All of this must comply with classifiers’ standards and integrate with the ship’s digital model (NUPAS-Cadmatic, AVEVA). STIGAL offers solutions that fit into these logistics, ensuring work continuity and predictable edge quality.

The production of commercial vehicles, transport bodies or storage systems balances between reducing weight and maintaining strength. Increasingly, S700MC fine-grained steels are being used, as well as mixed tube frame structures with variable cross sections. A key need therefore becomes the machining of high-strength profiles and plates without introducing an excessive heat-affected zone that could reduce fatigue performance. At the same time, high repeatability of the geometry of the mounting holes is required, because welding lines and robotic mounting cells do not tolerate deviations of more than 0.2 mm.

In addition, you need to ensure high programming flexibility to handle the increasing number of body variants for short runs. Data integration with PLM and MES enables cost control at the quotation stage and subsequent optimization of the shop layout. STIGAL has a portfolio of solutions that support these requirements, providing manufacturers with the tools for stable, scalable and ISO 3834-2 compliant production.

Companies building industrial halls, stadiums or bridge infrastructure work under high deadline and cost pressures. Every day of delay on the construction site means contractual penalties, so prefabricated parts must arrive on time and “fit” without additional adjustment. The industry expects cutting processes that guarantee parallel edges, accuracy of holes for HV bolts and preparation of chamfers for fillet welds according to the BIM model.

It becomes crucial to optimize material utilization – dynamic nesting and minimizing waste without increasing cycle time – because the margin is calculated in PLN/t. Full compliance with EN 1090-EXC3/EXC4 is also required, which means archiving of parameters and traceability of steel batches. At the same time, there is a growing demand for integration of cut-to-weld processes to minimize transport between nests and speed up prefabrication of nodes. STIGAL’s solutions address these needs, enabling structural manufacturers to increase productivity and assembly confidence while maintaining the highest quality standards.