Miller Introduces New Welding Technology, Fume Extraction Products at FABTECH 2011; Demonstrates Total System Solutions

Miller Introduces New Welding Technology, Fume Extraction Products at FABTECH 2011; Demonstrates Total System Solutions

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More than 35,000 people flooded Chicago's McCormick Place for FABTECH 2011, one of the world's largest gatherings of manufacturing and fabrication professionals. Miller's three booths at the show (Miller, Miller Welding Automation, ITW Welding North America) drew constant crowds with live welding demonstrations, new products and exciting promotions.

Miller Introduces New Welding Technology, Fume Extraction Products at FABTECH 2011; Demonstrates Total System Solutions

Mark Kadlec at Fabtech 2011 small.jpg
Published: December 18, 2011
Updated: February 5, 2020

New Product Introductions

Welding highlights from the show included the AWS Professional Welding Competition and the introduction of the Boy Scout merit badge for welding (watch a video on both here). Miller used the show to launch new expansions to its FILTAIR™ fume extraction product line, as well as advanced new welding power sources designed to enhance Pulsed MIG welding capabilities while also providing higher duty cycles and more welding power. New Functionality to Miller’s Axcess E with Insight was also introduced (click here for a video), and Miller Welding Automation showed off a few tricks of its own. Check out highlights below, and revisit all activities at the show at!

The Invision™ 450 MPa

The new Invision 450 MPa MIG/Pulsed MIG welding inverter is the big brother to the popular Invision 352 MPa. Optimized for use on thicker materials and larger diameter wires, the Invision 450 MPa offers manufacturers and fabricators 450 amps of Pulsed MIG welding power at 100 percent duty cycle. Additional features include:

  • Longer welding times with larger wire diameters for increased productivity, thanks to higher amperage and duty cycle
  • Additional Pulsed MIG programs for .052- and 1/16-inch wires and all the great programs found in the Invison 352 MPa
  • Simple interface and controls for operators
  • Improved Pulsed MIG welding arc with the ability to weld on a wider range of thicknesses
  • Synergic “one knob” controls that automatically adjust pulse parameters to match wire feed speed
  • Improved energy efficiency over older and non-inverter welding equipment

The new Invision 450 MPa is designed for extremely easy use: the operator selects the wire diameter, wire type, gas being used and wire feed speed and they are ready to weld. The machine features standard built-in programs for steel, metal-cored, aluminum, stainless steel, nickel, silicon bronze and copper nickel wires. Advanced arc controls provide a more robust, stable Pulsed MIG arc at very low arc length, which reduces heat input and provides the ability to weld on a wider range of material thicknesses. 

New FILTAIR™ Products

Miller introduced three new products to its FILTAIR product line at FABTECH 2011. The new introductions include the FILTAIR Industrial Centralized Fume Extraction Series, the FILTAIR 400 Industrial High-Vacuum Fume Extraction System, and the FILTAIR Automation Hood. Key features:

The FILTAIR Industrial Centralized Fume Extraction Series: The Series includes five base models (2,000, 4,000, 6,000, 8,000 and 12,000 cfm) and is extremely customizable to a wide variety of welding cells and applications. Requiring up to 65 percent less floor space than traditional cartridge collectors, the system combines Miller TruLock™ Filter technology with a Minimum Efficiency Reporting Value (MERV) 15 nanofiber filter pack to guarantee superior performance in immediately capturing up to 95 percent of all submicron particles (based on ASHRAE 52.2 test standards).

The FILTAIR 400: The FILTAIR 400’s surface-loading technology captures submicron particles at the surface, providing high quality weld fume filtration and cleaning quality, extending the life of the filter. The system offers automated filter cleaning for long periods of maintenance free operation. The four-port access means the unit can be centrally located while maintaining flexibility, especially when paired with FILTAIR accessories such as fume extraction guns.

The FILTAIR Automation Hood: Optimized for use with Miller’s PerformArc™ pre-engineered Robotic Welding Cells, the flexibility of the Miller design allows for multiple sized cells and variable filtration demands from station to station. The durable but lightweight design makes adapting to production changes easy. The lower-airflow design will reduce energy costs while maintaining excellent fume extraction.

The New AlumaPower™ 450 MPa

The AlumaPower 450 MPa is a dedicated aluminum machine with built-in synergic Pulsed MIG capabilities designed to increase power while maintaining ease of use. This new machine is rated at 450 amps at 100 percent duty cycle. The AlumaPower 450 MPa is one component of Miller’s Synergic AlumaFeed System, optimized for Pulsed MIG welding when matched with the XR AlumaFeed push-pull wire feeder and an XR AlumaPro™ or XR™ Pistol Grip push-pull welding gun. Benefits include:

  • Increased power efficiency over older and non-inverter welding equipment.
  • Longer welding times and increased productivity with larger 1/16-inch wires because of increased amperage and duty cycle.
  • Simple interface and controls make it easy to operate.
  • Quality Pulsed MIG welds through synergic operation with the XR AlumaFeed™ portable feeder.

The new Big Blue® 450 Duo CST

The new Big Blue 450 Duo CST is a dual-operator diesel engine-driven welding generator that features two CST 280 Stick/TIG inverters and 12,000 watts of continuous three-phase power in a single unit. Powered by Mitsubishi’s S4L2 4-cylinder diesel engine, the Big Blue 450 Duo CST provides increased productivity by allowing two welders to work off the same machine with two separate welding outputs. The machine offers superior performance on difficult Stick electrodes found in structural steel and fabrication applications, such as E6010, and excellent TIG performance for pipe fabrication and maintenance applications.

This Tier 4i compliant machine operates at a low 1,800 RPM, which reduces fuel use and keeps noise levels up to 10 dBa quieter than other models, improving work site communication and safety. Built within the same footprint as Miller’s industrial engine-driven welding generators, the Big Blue 450 Duo CST is a compact, reliable Stick/TIG welding system that truly allows companies to double productivity with one machine.    

Miller Welding Automation

Miller Welding Automation showcased an exciting new booth at FABTECH 2011, and in these two videos you will see extensive demonstrations of two Miller Welding Automation processes: dual robot tandem welding and adaptive fill welding.

For more information on Miller Welding Automation, visit 

Expanding Knowledge and Online Interaction

We also took the time to discuss key welding issues and topics with experts from Miller, Hobart Brothers and MAXAL, including answering your questions from home on issues such as 6010 electrode use and welding stainless steel. Check out the videos in this gallery to the left for more.

FABTECH 2011 was a blast for all of us and we look forward to next year’s show in Las Vegas. Whether we see you there in person or you join us for show coverage online, we’ll be glad to see you. Until next year, weld well and weld safe.