Miller and Gullco’s Hercules Welding System Takes Centre Stage at FABTECH
Miller Electric and Gullco International are making headlines ahead of FABTECH 2025 with the launch of Hercules, a cutting‑edge welding automation system.
Designed for high‑efficiency MIG welding, Hercules is tailored for heavy fabrication contexts where deposition speed and productivity are paramount. It brings together automation platforms from Gullco, power sources from Miller, Hobart’s specialised filler metals, and Tregaskiss MIG gun technology to deliver both high performance and streamlined integration.
What Makes Hercules Stand Out
Hercules isn’t just another MIG variant. Debuted by ITW in August 2022, it employs a hot‑wire technique—pre‑heating the electrode via a secondary power supply before the main arc fires. That kind of precise control over the filler metal leads to significantly heightened deposition rates and improved productivity.
What’s more, Hercules consistently delivers around 30 % more deposition than traditional MIG welding, cutting through bottlenecks and enhancing throughput.
Hercules vs. Traditional High‑Deposition Techniques
The welding world knows tandem GMAW, twin‑arc, and sub‑arc methods for high‑deposition—but they often introduce complexity and cost. Jason Ball, Miller’s automation sales manager, puts it plainly: “Hercules provides the high deposition rates akin to tandem GMAW, twin‑arc, or even sub‑arc welding without the complexity.”
Multi‑wire setups often struggle with arc stability and wire feeding, while sub‑arc demands flux handling and clean-up. Hercules avoids those headaches, offering a cleaner, more straightforward high‑deposition workflow.
Ideal for Fixed Automation and Heavy‑Fabrication Markets
Though Hercules began life in robotic applications, it shines brightest in fixed automation settings—especially for long, linear welds across sectors like heavy equipment, bridge building, and tunnel engineering.
Matt Kramer, Miller’s automation specialist, says it best: “Fixed automation is the space where Hercules is really going to shine in the welding market, and Gullco is the leader in this domain.”
Hercules Meets Gullco’s Tractor
At FABTECH 2025 (Chicago, 8–11 September), Gullco will reveal for the first time Hercules on a fixed automation, or “tractor”, platform. As Jeff Zook, Gullco USA’s president and general manager, boasts: “This is a game‑changing development in high‑deposition welding, and we are really excited to show this to the world at FABTECH.”
They’re achieving deposition rates measured in pounds per hour that rival or even surpass sub‑arc welding—yet with the adaptability and simplicity of standard MIG welding.
Industry attendees can experience a live demonstration at booth B15009.
Technical Highlights of the Hercules System
Dig a bit deeper, and Hercules proves itself a comprehensive plug‑and‑play powerhouse:
- Dual Power Supplies: One to sustain the arc, another to pre‑heat the filler wire for that hot‑wire edge.
- Hobart FabCOR® Hercules Metal‑Cored Wire: Engineered for high feed speeds and deposition rates.
- Tregaskiss Water‑Cooled Hercules Torch: Built for prolonged use under heavy-duty conditions.
- Auto‑Continuum™ 500 & XMT® CC/CV Power Sources: Handle advanced waveforms and pre‑heat control.
- Hercules Drive & Cable Pack: Designed for precise, high‑speed wire feed in robot or fixed automation setups.
What This Means for Industry Stakeholders
For construction professionals and fabrication managers, Hercules promises faster turnaround with fewer workflow disruptions. Investors might spot reduced operating costs and higher ROI in high-volume welding setups. Policymakers, especially those focused on infrastructure and labour productivity, could note its potential to raise national fabrication standards.
Winding Down on a High Note
With Hercules, Miller and Gullco aren’t just showing off a new welding technique, they’re rewriting the high‑deposition rulebook. By packing industrial strength into user‑friendly automation, they’re helping heavy‑fabrication industries work smarter, not harder.
At FABTECH 2025, the welding world will witness exactly how Hercules delivers on that promise. It’ll be worth watching, and welding, closely.
