20 years of CMT (Cold Metal Transfer)

(Wels, Austria, June 17, 2025) Fronius, a leading innovator in arc welding, is celebrating the 20th anniversary of its revolutionary Cold Metal Transfer (CMT) welding process. Since its introduction in 2005, CMT has transformed the industry and set new standards in precision, stability, and a variety of applications. The CMT process is based on a retractable wire movement, which enables controlled droplet transfer, ensures a stable electric arc, and minimizes heat input. This technology creates clean, virtually spatter-free weld seams that are also high-quality and have an excellent appearance. Another advantage of the CMT process is the low heat input to which the workpiece is subjected. This reduces distortion, which is a major advantage, especially when working with thin sheets as thin as 0.3 millimeters and temperature-sensitive materials. Precise control of the welding process helps to tackle the most demanding tasks with maximum precision. CMT offers the possibility of joining different materials together. For example, it enables the safe and reliable welding of galvanized steel and aluminum. This advantage opens up scope for creative solutions in the manufacturing process. Variety of Applications in Different Sectors “CMT has established itself over the past two decades as a versatile welding process used in numerous sectors. We are sometimes impressed by the diversity and creativity with which our customers leverage the advantages of CMT to solve their welding challenges,” reports Franziska Eichhorn, Strategic Product Manager at Fronius International. The automotive industry uses CMT, for example, to join thin sheet metal and lightweight materials such as aluminum. This ensures strong and reliable joints in vehicle frames and components. CMT has also proven itself in the aviation and aerospace industry, where the process enables the welding of high-strength, lightweight materials essential for the construction of aircraft and spacecraft. Furthermore, due to the excellent stability of the soldering process, CMT is used in 3D printing and the electronics industry to precisely join components using brazing. Smart Gap and Edge Detection with CMT The forward and reverse motion of the wire in CMT also revolutionized robotic soldering with the WireSense intelligent assistance system. This significantly improves seam quality and efficiency by identifying inaccuracies and deviations during production and correcting them through the CMT soldering process. The wire acts as a precise sensor, accurately determining the seam position and dynamically adjusting it. The result is material, time, and cost savings by reducing rework and scrap. CMT: A Future-Proof Solution “The perfect interaction of the components and the precision with which they are controlled play a decisive role,” Eichhorn insists, continuing: “The harmony with which our intelligent welding systems and Robacta Drive CMT, the second torch-mounted wire feeder, work together remains unrivaled and is continually being developed to meet the growing demands of the industry. And best of all, all intelligent Fronius systems can be easily expanded with CMT.” Over the years, the innovation leader has continued to refine CMT and develop optimized welding characteristic curves for specific applications, such as CMT Mix, CMT Cycle Step, CMT Cladding, and CMT Braze. LaserHybrid CMT, on the other hand, combines the advantages of laser welding with CMT technology. This combination stands out for its high speed, quality, and cost-effectiveness in applications involving high-strength steels and aluminum components. The highly concentrated laser beams, which penetrate the base material with high energy density, are immediately followed by the CMT process, which can increase bead volume and further reduce heat input. The latest advancement is the CMT Additive Pro characteristic curves optimized for metal 3D printing, which take additive manufacturing to new heights. We are Fronius Approximately 6,700 employees worldwide by the end of 2024, a current export share of 90%, and 1,752 active patents: that’s us, that’s Fronius. Founded in 1945, this regional one-person company has grown into a globally active industrial company with 37 international subsidiaries and a dealer network in more than 60 countries, but at its core, it remains an Austrian family business operating in the electrical and electronics industry. Fronius Welding continues to revolutionize welding technology, while Fronius Solar & Energy focuses on making the most of solar energy and optimizing battery charging systems for intralogistics. For 80 years, we have pursued a clear goal: to research electricity as a fuel and use it efficiently for the future. We develop products and solutions to ensure a future worth living, offering our customers a complete package, from pre-planning and consulting to continuous monitoring and service tailored to your needs. We are innovative. We are curious. We are Fronius. Fronius Welding The highest arc quality, deep customer knowledge, and a thirst for technical progress: We are innovation leaders in arc and robotic welding. We demonstrate our expertise with complete manual and automated systems, as well as intelligent welding solutions for Industry 5.0. Our offering is rounded out by intuitive welding equipment for manual welding applications, high-quality welding accessories, and effective protective products for user safety. As a global company, we offer regional service through local teams available to our customers worldwide. With our technologies, we set trends and create connections between metals, industries, and people.