Fronius Velo – Velocity Assistant for Manual MIG/MAG Welding
Fronius Velo is a velocity assistant for manual MIG/MAG welding. It helps the welder hold the torch steady and keep a constant travel speed and stick-out, so long seams come out even, whoever is welding. Velo is a system add-on for Fronius TPS/i power sources from 320 A and iWave Multiprocess PRO systems, so every set-up is different: talk to us and we’ll work out the right package with you and Fronius.
Velo is built to suit your power source and work, so we quote each system. Call 0141 959 5666 or email info@weldsafe.co.uk.
- Next-day delivery to UK mainland when ordered by 2pm: £8.35 ex VAT, free on orders of £100 ex VAT and over
- Free collection from our Scotstoun warehouse
- Secure card payments
- Expert advice: 0141 959 5666
- Trade accounts available – apply online
Constant travel speed
The Velo wire sets the pace, so the speed stays the same from start to end of the seam.
Constant contact tip-to-work distance
Stick-out is held steady for even heat input and a consistent weld.
Less strain on long seams
The welder simply holds the torch, with less cramping and fatigue on long runs.
Up to robot-like speeds
Under certain conditions Velo reaches speeds comparable to robotic welding.
How Velo works
At the heart of Velo is a second wire, the Velo wire. It runs without an arc and without shielding gas. It touches the workpiece in its solid state and drives the torch forward by friction, so the Velo wire's feed speed sets the welding speed.
It holds the contact tip-to-work distance constant and pushes the torch along the seam edge, notch or chamfer, with no special seam preparation. It adds very little filler, because wire use matches the seam length.
“If you allow yourself to relinquish some control, you can now produce perfect welds in manual welding at unprecedented speed by simply holding the torch.”
Test users report noticeably less strain and a significant increase in precision and weld quality.
For beginners and experienced welders
Beginners get high-quality welds quickly, thanks to the guidance.
Experienced welders get relief on long or complex welds, with less cramping and fatigue and consistently high seam quality.
Under certain conditions, Velo reaches speeds comparable to robotic welding.
Where Velo fits
Applications
- Commercial vehicles and transport
- Heavy machinery
- Steel construction
- Apparatus and vessel engineering
Materials
- Steel
- Chrome-nickel (stainless) steel
- High-strength steel
- Thin and thick sheet
Processes
- Standard
- LSC
- Pulse
- PMC
- CMT
Built for real workshops
- The Velo holder rotates 360° without tools and locks in place.
- The components unclip and can be set aside when access is tight.
- Works in all positions, including 360° pipe welds and multi-layer welds.
- The 5 m Velo wire feeding system gives a large working range.
- Switch Velo on and off at the torch, so you can move between assisted and fully manual welding at any time.
Simple to retrofit
If you already have a Fronius TPS/i (320 A or above) or an iWave Multiprocess PRO, you need three things:
- the Velo wire feeder (WF 25i Velo)
- a torch adaptor with the Velo wire feeding system
- the OPT/i Velo software activation
No complex conversion is needed. Starting from scratch? Pair Velo with a new Fronius TPS 320i C PULSE Watercooled Package or Fronius iWave 300i 400i 500i AC/DC Multiprocess PRO.
Is Velo right for you?
Velo depends on your power source, torch, wire and the work you do, so we don't sell it online. Tell us about your application and we'll come back to you with advice and a quote, working with Fronius UK where needed. If you already have a TPS/i or iWave, let us know the model and serial number and we'll check whether it can be upgraded.
Available since autumn 2025 · patent pending
Photos: Fronius International GmbH
Downloads
Download the Velo brochure (PDF) (PDF, 15.0 MB)
Enquire about Velo
Tell us about your power source and the work you do, and we'll come back to you with advice and a quote.
Or call 0141 959 5666 / email info@weldsafe.co.uk
