Enhancing Welding Research and Process Monitoring at Cranfield University

16th January 2026

Enhancing Welding Research and Process Monitoring at Cranfield University

Project Scope

The Cranfield University Welding and Additive Manufacturing Centre is a renowned research institute focused on driving practical improvements for industry. Welding process automation is a key area of research for the centre, with a focus on process monitoring, quality control, and assurance. Cranfield University’s Dr Wojciech Suder highlighted that the perception of welding as a traditional process doesn’t reflect its crucial role in many manufacturing industries. The research undertaken in the Welding and Additive Manufacturing Centre stimulates improvements across sectors such as aerospace, energy, defence, and more, highlighting how integral welding is to driving innovation in key manufacturing sectors.

Xiris Automation

TPS Weldtech partnered with Cranfield University and the Welding and Additive Manufacturing Cen-tre to improve its welding process monitoring ca-pabilities. Through introducing Xiris Automation’s advanced imaging technology and providing project support for the cameras’ implementation, TPS sup-ported the research team to gain insights into their welding and additive manufacturing processes, improving the accuracy and efficiency of their fabri-cation processes and quality control.

NIR Weld Camera System

The Challenge

Modern welding and large-scale additive manufacturing processes are crucial to sectors like aerospace, automotive, energy, and renewables. Universities leading research in these fields play a significant role in developing the technologies and skills that drive industrial progress – but monitoring and verifying complex welding processes can be challenging, time-consuming, and expensive.

Traditional inspection methods often depend on subjective visual checks or limited sensor data, such as temperature readings. These approaches don’t always capture the full picture of what occurs at the fundamental level of feedstock melting and meltpool generation, making it difficult to optimise performance, verify results, or fully understand process behaviour.

Standard camera systems are not suitable for filming these bright events. The intense brightness of the welding arc, reflections, and plasma interference can impair image quality, and many imaging systems are complicated to set up and not ideally suited for research environments and fabrication workshops. The Cranfield University Welding and Additive Manufacturing Centre required a robust, high-quality and compact imaging system capable of providing clear, reliable process data and integrating seamlessly into its industrial workshop environment.

Our Solution

To address this challenge, TPS WeldTech partnered with the Welding and Additive Manufacturing Centre to identify the best technology for their needs, supply the Xiris Automation cameras and support the team at Cranfield with TPS’s technical expertise and integration assistance. Through a decade-long partnership with Xiris Automation and extensive experience with its weld-monitoring and inspection cameras, TPS introduced a sophisticated video-imaging system selected for industrial welding and manufacturing at the Welding and Additive Manufacturing Centre. The Xiris system provides exceptional image quality and process insight, even under the demanding conditions of high-intensity welding environments.

Key Features

• Reliable acquisition rate with video imaging at up to 60 frames per second, capturing fine detail in both the welding arc and melt pool.

• Compact, user-friendly equipment, ideal for research and teaching laboratories.

• Dynamic brightness adjustment allowing it to work with processes with fluctuating light output.

• Digital qualification and verification tools assist researchers in collecting accurate data at the required scale.

• Training and technical support from TPS WeldTech, ensuring a smooth setup and ongoing success.

This blend of technology and expertise offered WAAM (Wire Arc Additive Manufacturing) researchers a reliable view into the process – allowing them to see, record, and analyse welding procedures and outcomes in ways previously unavailable.

The Outcome

Thanks to the partnership with TPS WeldTech and the introduction of Xiris Automation imaging systems, Cranfield University’s Welding and Additive Manufacturing Centre has greatly improved its research capacity and understanding of all the open arc welding processes.

The new imaging systems have:

• Improved process monitoring and quality assurance, delivering clearer and more reliable data.

• Decreased the time needed to set up and validate tests in the work-shop; made training and sharing results more engaging through visual insights that animate complex welding processes.

• Supported research into automation, digital qualification, and new process development.

By implementing these advanced imaging systems, TPS WeldTech has supported the research centre to shift from conventional observation methods to a modern, data-driven approach – improving research out-comes. This collaboration highlights how the right technology and ex-pertise can bridge the gap between academic research and industrial application, fostering the next generation of welding and manufacturing innovation.

Why Choose TPS Weldtech?

We collaborate closely with our customers, providing decades of welding expertise and experience, premium equipment, and hands-on support to help you succeed.

Operating from strategic locations in Scotland and England, we provide comprehensive welding, robotic and cutting solutions to clients nationwide. Our highly skilled engineers deliver expert technical support to ensure seamless and safe automation integration.

TPS has been a long partner and supporter of our research and teaching. Throughout the years they provided training, support and demonstration of various equipment, their engineers are always friendly and helpful in sharing the latest industrial practices in welding development. They visit us on a regular basis to present novel monitoring equipment. The Xiris welding camera, for example, has been so successful in our context that we have more than ten systems installed in our lab. This is thanks to the great support and customer service that we have been receiving throughout the years.

Dr Wojciech Suder, Senior Lecturer in Laser Processing and Additive Manufacturing Cranfield University

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