MANUFACTURER
CNC MACHINES
CNC cutting systems
and production automation

The offshore and onshore energy sectors rely on high-strength materials, with thicknesses reaching up to 300 mm, in environments where every hour of downtime results in losses amounting to millions. Therefore, absolute process reliability, equipment resistance to salt spray, moisture, and dust, and the ability to process high-impact steel without compromising edge quality are critical. Workpieces must emerge from preparation with X, Y, or K bevels of perfect geometry to reduce multi-pass welding time and minimize the risk of RT/UT nonconformities.

The DNV, NORSOK, and EN 1090-EXC4 standards, in turn, require full traceability, automatic archiving of cutting parameters, and the ability to generate a QA report at the inspector’s request. Given the locations of these projects—ranging from offshore wind farms to FPSO modules—production lines must be modular, easy to relocate, and capable of operating 24/7. STIGAL provides solutions designed specifically for these extreme conditions, combining productivity with operator safety and compliance with rigorous industry standards.

Shipyards operate on a project basis, where the schedule for hull blocks is synchronized down to the hour with the cranes and construction section lines. The top priority is high cutting throughput for hull panels and long structural sections while maintaining a tolerance of ±0.5 mm on lengths exceeding 20 m. Any inaccuracy results in costly trimming and adjustments during block assembly, and any excessive weld gap leads to additional kilograms of welding material and the need to correct distortions.

The industry therefore requires processes that simultaneously cut the contour, chamfer the edges, and perform marking of assembly reference points to reduce the time needed to fit the sections together. In repairs, on the other hand, flexibility is the priority: the ability to quickly machine one-of-a-kind components, often made of soiled or corroded steel. The entire process must comply with classification society standards and integrate with the ship’s digital model (NUPAS-Cadmatic, AVEVA). STIGAL offers solutions that fit within this workflow, ensuring operational continuity and predictable edge quality.

The production of commercial vehicles, transport bodies, and warehouse systems strikes a balance between weight reduction and maintaining strength. Fine-grained S700MC steels and mixed frame structures made of tubes with variable cross-sections are being used more and more frequently. A key requirement, therefore, is the machining of high-strength profiles and steel plates without introducing an excessive heat-affected zone that could reduce fatigue performance. At the same time, high repeatability of the mounting hole geometry is required, as welding lines and robotic assembly cells do not tolerate deviations greater than 0.2 mm.

In addition, a high degree of programming flexibility is required to accommodate the growing number of body variants in short production runs. Data integration with PLM and MES enables cost control during the quoting phase and subsequent optimization of the shop floor layout. STIGAL’s portfolio includes solutions that support these requirements, providing manufacturers with the tools for stable, scalable, and ISO 3834-2-compliant production.

Companies that build industrial facilities, stadiums, or bridge infrastructure operate under intense time and cost pressures. Every day of delay on the construction site results in contractual penalties, which is why prefabricated components must arrive on time and “fit” without requiring additional adjustments. The industry expects cutting processes that guarantee parallel edges, accuracy in hole positioning for high-strength bolts, and the preparation of bevels for fillet welds in accordance with the BIM model.

Optimizing material utilization —dynamic nesting and minimizing scrap without increasing cycle time—is crucial, because the margin is calculated in PLN per metric ton. Full compliance with EN 1090-EXC3/EXC4 is also required, which means archiving parameters and ensuring the traceability of steel batches. At the same time, there is a growing need for the integration of “cut-to-weld” processes to minimize transport between workstations and accelerate the prefabrication of joints. STIGAL’s solutions address these needs, enabling structural manufacturers to increase productivity and ensure reliable assembly while maintaining the highest quality standards.