Fabrication of a Movable Welding Arm for Enhanced MIG Welding Efficiency

Wee, Jadrien Lun Tai (2026) Fabrication of a Movable Welding Arm for Enhanced MIG Welding Efficiency. Final Year Project (Diploma), Tunku Abdul Rahman University of Management and Technology.

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Abstract

This project focuses on the design and fabrication of a movable welding arm for MIG welding. The main objective of this project is to improve welding stability, reduce operator fatigue and achieve more consistent weld quality during welding operations. The methodology includes design development, material selection, fabrication, assembly and validation. The movable welding arm part of the designed using CAD software and fabricated using mild steel because of it strength and durability. The system consists of a base structure, movable arm, joints and a welding torch holder. Experimental testing was conducted to evaluate the performance of the system. However, the results showed the movable welding arm did not perform as expected. The main issues identified include excessive weight of the arm, insufficient motor torque and failure of the 3D printed gear used in the movement mechanism. The gear developed cracks during operation and eventually fractured due to high stress. Despite the unsuccessful performance, this project provides valuable insights into mechanical design, motor selection and material limitations. Several improvements are suggested for future work include the use the lighter materials, selection of higher torque motors and replacement of 3D printed components with stronger materials such as casted metal parts. Overall, this project contributes to the understanding of the movable welding arm design and highlights important factors that must be considered for successful implementation in welding applications