U-NEEK Bending elevates welding with TRUMPF TruLaser Weld 5000: Empowered by customer insights and a vision for onshore innovation

To meet rising customer demands for higher-quality, consistent, and efficient welding processes, U-NEEK recognised the need to transition from traditional manual welding to an automated system. This shift was essential to address customer expectations and position the company as a leader in advanced welding technologies. Their solution? The TRUMPF TruLaser Weld 5000, supplied and supported by Headland Technology.

About U-NEEK Bending Co. Pty Ltd: Located in Dandenong South, Victoria, U-NEEK Bending Co. Pty Ltd has been a pioneer in metal forming, bending, rolling, and welding since its founding in 1964. Renowned for its advanced engineering solutions, U-NEEK has established itself as a leader in delivering high-quality components across industries such as power generation, automotive, transport, defence, and mining. Employing 44 full-time staff, the company maintains its reputation for precision and innovation through its relentless pursuit of excellence. More about U-NEEK

Challenge

U-NEEK faced increasing pressure from its customers to deliver stronger, more consistent welds at scale. Manual welding methods, while effective, introduced variability and required significant human input, leading to limitations in quality and production capacity. Additionally, a nationwide skills shortage in the welding industry presented challenges in attracting and retaining qualified welders.

The company recognised that transitioning to automated laser welding was the key to overcoming these challenges. But before making the investment, U-NEEK took a bold step: they reached out to their existing customer base to understand how such a transition might impact their clients’ businesses. The feedback was overwhelming. Customers expressed excitement and validated the need for advanced laser welding capabilities, which are rare in Australia. Many even shared that they would move production back onshore to benefit from U-NEEK’s enhanced capabilities, reducing lead times and costs.

Solution

After thorough research, U-NEEK selected Headland Technology to provide the TRUMPF TruLaser Weld 5000 system. Key factors influencing the decision included:

• Proven performance: The TruLaser Weld 5000 offered high-strength, consistent welds, significantly improving weld quality compared to traditional methods.
• Trust in Headland: U-NEEK values Headland’s product knowledge, aftermarket support, and professionalism.
• Customer validation: A site visit to a Queensland facility using the same machine allowed U-NEEK to see the system’s capabilities in action and gather insights from an existing user.

This decision enabled U-NEEK to address customer needs for innovative welding solutions, setting the stage for growth in their core markets and beyond.

Implementation

U-NEEK’s team, led by Quality Manager – Welding Coordinator (IWT) Mathew Billman, worked closely with Headland to integrate the TruLaser Weld 5000 into their operations. The process began with advanced training at TRUMPF’s facility in Germany, equipping engineers with the expertise needed to optimise the system’s capabilities.

Headland’s team ensured a seamless installation and provided immediate technical support, resolving any challenges within minutes. The machine’s intuitive programming and user-friendly interface accelerated employee adoption, while its automated processes quickly demonstrated improved efficiency and quality.

Although some senior welders were initially hesitant about the transition, younger employees embraced the cutting-edge technology. The system also helped attract new talent, addressing the skills shortage and boosting workforce morale.

Results and Impact

Since adopting the TruLaser Weld 5000, U-NEEK has experienced transformative results:

• Enhanced efficiency: Automated laser welding processes have reduced errors and increased output consistency.
• Expanded market reach: The new technology has allowed U-NEEK to service additional industries needing unique components.
• Competitive advantage: With certifications unlocked through the system’s capabilities, U-NEEK has secured new contracts and diversified its portfolio.

Lessons learned

Mathew Billman advises other companies to embrace innovation early:

“Investing in technology before having specific jobs lined up was a risk, but it has already paid off. The opportunities this machine has opened for us have been immense.”

Future outlook

Looking ahead, U-NEEK plans to expand its operations, adding 1,000 sqm of space to accommodate growing demand. The company aims to further explore opportunities in defence and rail, potentially integrating additional laser welding systems and complementary technologies to enhance its capabilities.

Why Headland?

U-NEEK highlights Headland’s professionalism, responsiveness, and comprehensive support as key contributors to the project’s success.

“Headland’s turnkey approach and expert team made the entire process effortless. Their support has been invaluable in helping us achieve our goals.” – Mathew Billman, Quality Manager – Welding Coordinator (IWT), at U-NEEK.

By partnering with Headland and adopting the TRUMPF TruLaser Weld 5000, U-NEEK has set a new standard for excellence in welding, ensuring its leadership in the industry for years to come.

Are you ready to elevate your welding processes and meet growing customer demands for higher weld quality and consistency in the sheet metal fabrication industry?

Our sheet metal experts are ready to help you tackle the specific challenges of your business. Whether you’re seeking to improve efficiency, increase weld strength, or expand into new markets, we understand that every company has unique requirements. If you ever need a unique solution tailored to your specific needs, our team is here to support you every step of the way. Let us help you get there!