About Firefly Welding Machine

The Firefly welding machine is a ‘bug and band’ semi-automatic arc welding machine. The main purpose of the Firefly equipment is to improve the productivity of the skilled welder. This is achieved by continually producing a consistent weld result with the latest equipment and technology. Firefly is a fully integrated digital welding system and is compatible with modern inverter systems and related welding equipment such as robotic wire feeders.

Firefly System Components

The design and functionality of the Firefly weld head has been achieved by years of field experience and listening to feedback from welders. The robust design features can cope with the most demanding applications, terrain and, of course, welders!

The first thing people notice is the compact size. Firefly is relatively small. This enables the machine to be used effectively where space is limited. Firefly’s small size also results in a manageable lifting weight of about 10kg.  

The Firefly weld head has a simple band clamping latch mechanism to enable fast and effective clamping of the weld head to the band. Positioning the weld head on the workpiece is straightforward by using a ‘free wheel’ setting before final locking of the weld head into the chosen position. Removing Firefly from the band is equally simple with a latch release mechanism

Firefly’s torch holder can accommodate torches of varying sizes depending on the particular job to be carried out.

Firefly Specifications

Minimum Weld Diameter 6 inches (150mm)
Maximum Weld Diameter Unlimited
Maximum Wall Thickness Unlimited
Maximum Oscillation Width 3.6 inches (92mm) independently adjustable in 0.0001 inch (0.01mm) increments
Dwell Time 0-8 independently adjustable in 0.01s increments
Travel Speed 0-270 inches (0-6858mm) per minute
Wire Capacity 0.8 – 2.0mm
Machine Weight 10kg Wire off board model
14kg Wire on board model (without 5kg spool)
Machine Dimensions Length 30cm
Width 17cm
Height 27cm to 33cm

The Firefly control box is the heart of the system. The control box incorporates modern digital technology for precise control of key welding parameters.

The weld parameters are entered into the control box using Firefly’s HMI programming pendant. To help ensure a consistent weld result, the weld parameters can be locked down or the level of allowable welder adjustment can be set.

The Firefly control box is compatible with suitable inverters from all manufacturers.  

Firefly is a semi-automated machine – the welder must use their skill to make final adjustments to the weld by operating the remote once the weld is underway.

With constant use throughout a welding shift, Firefly’s operator’s remote is designed for ease of handling and operation. Much attention has been given to the size, weight and physical robustness of the unit. Similar attention has been given to the positioning and colour of the positive click buttons. The remote incorporates leading digital technology to enhance response times.

A hi-visibility display screen enables ease of parameter identification and quality buttons offer long life and reliability.

The remote is connected to Firefly’s control box and controls functions such as travel speed, travel direction and oscillation.

Each Firefly remote is inter-changeable with all Firefly control boxes.

After extensive field testing, the ease-of-use design features and physical robustness of the remote will suit most users. However, other design options are available.

Firefly uses a ruggedised laptop computer as a programming pendant to enable welding parameter set-up in a familiar windows environment – 50 parameter memories come as standard. Each Firefly HMI is compatible with all Firefly control boxes, so only one HMI is required per worksite.

The Firefly HMI has a ‘team viewer’ remote assist capability. This feature enables on-line diagnostics to be carried out by technicians. Firefly’s HMI allows the user to download actual weld programming data to a USB memory stick for further processing in an Excel spreadsheet format.

Firefly is a ‘bug and band’ system – the bug or weld head runs on a travel guide band (sometimes called a track or ring) which is mounted to the workpiece.

With set-up times a key factor for most welding projects, much attention has been given to aid this important process. The Firefly weld head has a simple band clamping latch mechanism to enable fast and effective clamping of the weld head to the band. Positioning the weld head on the workpiece is straightforward by using a ‘free wheel’ setting before final locking of the weld head into the chosen position.

Removing Firefly from the band is equally simple with a latch release mechanism. Mounting the guide band to the workpiece is aided by a simple attach and release mechanism on the guide band. Firefly can operate on various band designs – orbital on an external track or orbital on an internal track. Firefly also has a linear capability; where it can operate on a flat track, both vertical and horizontal.

For applications where the workpiece is neither round or linear, but oval or curved instead, a specially modified Firefly is possible. Firefly has a bi-directional capability on all band configurations – there is no need for separate left and right hand machines.

The Firefly control box can include an integrated arc welding data logger and monitoring unit.

The unit offers a built-in solution – a seamless integration with minimal start up times and no external cabling.

Mounted to the front of the Firefly control box, the eight-inch touch screen unit will monitor variables such as arc voltage, arc current, wire feed speed, travel speed, arc time and traverse speed.

Data is captured digitally, direct from the weld power source.


The purpose of the unit is to aid the decision-making process by providing users with information about the actual weld.

  • Real time weld monitoring – the unit measures the defined variables to enable the comparison of those variables to upper and lower limits within the weld procedure, then communicates the results of this comparison.
  • Weld data acquisition – the unit measures, displays and stores the defined variables to evaluate specific arc characteristics.
  • Production data – the unit provides various layers of productivity related information.

The value of the unit comes when the output is compared to the pre-set tolerances for the workpiece.

Armed with real time information, the user can quickly identify potential process variances and take appropriate remedial action to ensure the weld procedure is followed.

Using the data logger

Firefly’s data logger is already fully integrated; there is no additional setting up time.

The operator enters basic data about the weld – such as user ID, weld number, welder position – then it’s good to go.

Just press ‘arc-on’ and the unit starts to record the weld data.

Keeping up with information demands

Weld records are a significant part of the huge amount of documentation required to achieve weld validation.

Firefly’s data logger will allow the actual weld data to be exported directly to a computer for compilation of weld records for the job – there is no need to re-enter data manually from reams of printed material.

If printed documentation is required for QA purposes, data can be printed from automatically generated PDF reports.

Contact Us

If you are interested in a demonstration of Firefly’s capabilities, please get in touch.