In many industries - including general mechanical engineering, mobile hydraulics and plant engineering - fixed, reliable fastening points are essential. Typical methods such as welding base plates, screwing or bonding each have specific strengths, but reach their limits in certain assembly situations. Stud welding closes this gap by enabling a firm, punctual and highly reproducible connection. Users primarily utilise the process where space is tight, sheet metal structures are thin or high processing speeds are required.

In stud welding, welding studs with internal threads are permanently attached to the substructure. These studs replace conventional weld-on plates for clamps in the standard and double series in accordance with DIN 3015 Part 1 and Part 3. The process utilises a stud welding device with which the studs are completely fused to the surface at specific points and in a very short time.

A spacer adapter ensures that two studs are positioned exactly at the required distance from each other. A plastic spacer plate is then attached to create the required distance between the clamp body and the substructure. The actual installation of the clamp is then carried out as usual.

Stud welding has established itself primarily due to its practical advantages. In daily use, users benefit from

• Savings potential for larger processing quantities thanks to short process times and low preparation costs

• Greater flexibility in mounting positions, especially for overhead or wall mounting

• Reduced reworking, as the spot welds are executed very cleanly

• Minimal material distortion due to the slight influence of heat - crucial for thin-walled constructions

• Reduced risk of corrosion due to the full-surface connection between the bolt and the substrate

These factors mean that the process is economically attractive for both series production and project-orientated assembly.

Since its first introduction, stud welding has established itself as the standard for many OEMs and hydraulic service providers. The process offers clear advantages in terms of reproducibility and process reliability, particularly in series production. At the same time, it is increasingly being used in smaller project environments where flexible assembly conditions are required.

The system is no longer limited to clamps in accordance with DIN 3015, but can also be combined with customised fastening solutions - for example with components for guiding cable ties or tension belts. As a result, it fits seamlessly into the overall modular system of various fastening methods, which also includes adhesive and screw solutions as well as different rail systems.

In practice, the benefits are particularly evident in areas of application where:

• Sheet thicknesses vary or are limited

• assembly stations are difficult to reach

• installation space is tight and classic base plates would be a hindrance

• many fixing points have to be set in a short time

Users report particular advantages for retrofitting or repairs, as fixing points for STAUFF clamps can be added quickly and reliably.

Stud welding will continue to gain in importance wherever compact designs, low material thicknesses or high cycle times play a role. Due to the ongoing diversification of fastening elements, the process is becoming increasingly flexible and complements other methods without replacing them.

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