Stainless Steel Pipe Welding - Case Study
Case Study Overview
Leanfabs partnered with SPA Design UK, a leading manufacturer of motorsport instrumentation and components, to produce a batch of precision aluminium cylinders for a critical product line. The project required TIG welding specialists capable of delivering airtight, full-penetration welds on thin-wall Aluminium 6082 with exceptional cosmetic quality. Using custom purging rigs, controlled heat inputs, and meticulous surface handling, Leanfabs achieved flawless results across all units. Each weld met SPA Design’s rigorous standards for strength, consistency, and visual finish—earning praise for the “clean weld finish” and “perfect repeatability” essential in high-performance automotive applications.
Project Overview
Client:
SPA Design UK – Manufacturer of high-performance motorsport instrumentation, sensors, and components.
Sector:
Motorsport / High-Performance Automotive
Project Scope:
SPA Design required a batch of precision-fabricated aluminium cylinders for a critical product line. The parts demanded flawless welds, airtight integrity, and an immaculate external finish, as they would be used in high-performance environments where reliability and aesthetics both matter.
Challenges:
- TIG welding thin-wall aluminium components to tight tolerances
- Achieving airtight, full-penetration welds around curved surfaces and fittings
- Maintaining distortion control and cosmetic perfection
- Meeting high standards for visual weld consistency and surface cleanliness
- Ensuring repeatability across multiple units
Our Solution:
- Material: Aluminium 6082 and machined components
- Process: Precision TIG welding using back-purging and controlled heat inputs
- Setup: Custom purging rig and consistent joint prep for uniform weld quality
- Finish: Final surface clean-up and handling with soft cloth and gloves to prevent marking
Outcome:
- Successfully delivered a batch of high-quality aluminium cylinders
- Every weld passed client inspection for strength, visual quality, and airtight integrity
- SPA Design highlighted the “clean weld finish” and “perfect repeatability” across units
Client Feedback:
