Fronius international was founded in 1945 with the welding technology division being founded in 1950.
The first Fronius Virtual welder was launched in April 2010, designed as a digital training tool to reduce consumption (gas, metal, filler wire) and improve safety during training.
Since the Virtual welders launch back in 2010, there has been many iterations of the system which brings us to today’s Welducation Simulator, launched in 2024, the Welducation Simulator is consistently being remotely updated, meaning there will be little need for any further versions. Using augmented reality (AR) to provide a realistic, cost-effective training solution. Supporting this system is the welding campus platform for theoretical learning, where teachers or apprenticeship providers can create welding courses.
In February 2019 Fronius International partnered with the University of Applied Sciences Upper Austria and Training Centre Fohnsdorf (SZF) to evaluate the value and effectiveness of the Welducation Simulator as a solution to the limitations of traditional welding training.
Background
Traditional welding training faces common challenges including high material and operational costs, safety risks, restricted practice opportunities and inconsistent learning. SZF, which trains around 140 welding trainees each year, adopted the simulator and took part in a research project to assess its performance compared to conventional training methods.
Key Findings
- Higher training efficiency: Virtual training brought 65% more active welding practice time, over three times more practice tasks, and nearly 93% more weld output per day. When 30% of practical training was conducted virtually, total training time was significantly reduced while learning outcomes remained consistent.
- Faster learning: Trainees can repeatedly practice foundational skills without resource limits, learn at their own pace, and achieve consistent competency levels.
- Substantial cost savings: At SZF, the annual cost of traditional training reached €396,176.70. Virtual training saves €0.55 per plate welding seam and €2.95 per tube welding seam, with per-trainee material savings ranging from €74.45 to €231.88.
The investment in the simulator can be recovered through material savings alone after training 106 to 333 participants, depending on the training scope.
Conclusion
The Welducation Simulator proves to be an effective core training tool rather than just a supplementary resource. It optimises trainer workload, expands training capacity and ensures consistent training quality. Integrating it into standard training programmes can help organisations cultivate skilled welders more efficiently, safely and cost-effectively.
Global Market Trends:
Industry estimates place Fronius within the top tier of virtual welding simulator providers. This is believed to be driven by the increasing demand for safe and sustainable training.
The global virtual welding simulator market is growing at a Compound Annual Growth Rate (CAGR) of 8.3%. This is expected to reach an estimated £165,000,000.00 by 2031.
Between 2025 and 2026 Fronius were estimated to hold approximately 15% of the global virtual welding simulator sales. A key driver for this statistic is the critical shortage of skilled welding specialists and a need for cost-effective, resource-efficient training.
As an official Fronius distributor and trusted supplier of advanced welding technology in the South-East of the UK, Miganglia is perfectly positioned to provide the Welducation Simulator directly to training providers looking to modernise their welding programmes. With the market set to continue expanding, Miganglia’s partnership with Fronius places us at the forefront of innovation. Miganglia not only supply the technology but also bring local expertise, technical support and on-site training, making it easy for businesses to adopt this advanced training method.
If you have read this and would like to find out how Miganglia can support your manufacturing business, please contact us here.
