Welded Assemblies for Machine and Plant Engineering

Welded assemblies determine the stability, dimensional accuracy, and service life of a structure. EMAG Production manufactures sophisticated assemblies from sheet metal and steel for external customers who require robust welded components, precision further processing, and industrial-grade quality – all from a single source.

Welded assemblies: designed for heavy-duty use, precision-manufactured

At the EMAG Production site in Zerbst, complex assemblies are produced for mechanical engineering, automation, housing and cladding technology, as well as for load-bearing machine structures. The sheet metal fabrication department is geared toward producing sophisticated welded assemblies: from cutting and folding to welding, surface finishing, and final assembly. These include, among other things, machine bases, electrical cabinets, automation conveyors, machine panels, work area panels, machine enclosures, and welded subassemblies.

At EMAG Production, we combine in-house manufacturing capabilities with many years of experience in machine tool manufacturing. Approximately 60 to 70 percent of the manufactured parts are produced in-house; sheet metal fabrication is a central production area staffed by experienced specialists, equipped with modern machinery, and supported by well-established quality processes.

Welding of thick sheet metal and complex assemblies

For welded assemblies in mechanical engineering, welding performance alone is not enough. What matters most is the interplay of design-appropriate preparation, low-stress fabrication, reliable weld execution, and dimensionally accurate post-processing. Especially with thick sheet metal, load-bearing frames, base bodies, or large-format cladding, welds, tolerances, and subsequent mounting surfaces must be coordinated from the outset.

EMAG Production manufactures welded assemblies for applications where stability, function, and repeatability are paramount. Welding stations with a capacity of up to 6.3 metric tons enable the machining of heavy assemblies and robust steel structures.

Processes for welded assemblies

Procedure	Scope of Application	Technical Benefits
Manual welding	Individual parts, custom designs, complex geometries	High flexibility for assemblies with many variants
MAG welding	Steel, thick sheet metal, machine frames, load-bearing structures	Cost-effective arc welding with high deposition rate
TIG welding & laser welding	Precision welds, visible areas, thinner materials, and stainless steels	Clean weld formation and controlled heat input
Spot welding & projection welding	Sheet metal joints	Fast joining without a continuous weld
Stud welding with spark ignition up to D = 12	Bolts, threaded bolts, fastening points on thicker sheets	High-strength joint for assembly and fastening applications
Stud welding with tip ignition	Thinner sheet metal	Clean fastening points

The selection of the welding process depends on the material, sheet thickness, component geometry, load, appearance, and subsequent machining steps. For each welded assembly, the process is selected to ensure a balance between function, dimensional accuracy, and cost-effectiveness.

From sheet metal processing to the finished assembly

A high-quality welded assembly begins before the first weld is made. In Zerbst, complex assemblies therefore go through several coordinated process steps: work preparation, laser cutting, bending, welding, blasting, powder coating, and assembly. This integrated process chain reduces interfaces, shortens coordination times, and improves the quality of the finished assembly.

For the upstream sheet metal processing, equipment available includes CNC-controlled laser cutting machines, modern bending machines, and press brakes.

Typical welded assemblies

EMAG Production specializes in technically sophisticated assemblies that must function reliably in industrial environments.

Typical applications include:

Customers benefit from the in-house manufacturing capabilities at our facility, particularly for combined welded assemblies: Welding, machining, surface treatment, assembly, and quality assurance can be coordinated on a project-by-project basis.

Benefits for customers

High vertical integration

Fewer interfaces, better coordination, shorter processes

Experience in machine tool manufacturing

Expertise in precision, durable, and long-lasting designs

Welding stations up to 5 metric tons

Suitable for heavy-duty and robust welded assemblies

Modern quality assurance

Documented dimensional accuracy and controlled manufacturing quality

Sheet metal fabrication, surface finishing, and assembly

Complete assemblies instead of individual manufacturing steps

Expertise in both series production and individual parts

Suitable for prototypes, variants, and recurring assemblies

Welded assemblies according to drawings or project requirements

EMAG Production manufactures welded assemblies according to drawings, CAD data, or technical specifications. Details relevant to manufacturing can be evaluated as early as the quotation and project phases: seam preparation, accessibility, warpage, sheet metal thicknesses, bend sequences, assembly points, surface requirements, and subsequent machining.

The goal is a welded assembly that is not only manufacturable but also functions reliably in its subsequent application. This is precisely what EMAG Production stands for: industrial welding expertise, experience with complex mechanical assemblies, and a manufacturing environment designed for precision, stability, and on-time delivery.