How the ERGOPLUS ‘Dragon’ is firing up MIG welding

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Welding requires precision, endurance, and, above all, the right tools. A professional welder tells us how the ERGOPLUS MIG torch not only enhances comfort but also elevates welding performance to new heights.

Ergonomic Design for Enhanced Performance

"The ERGOPLUS MIG torch is like welding with a fire-breathing dragon." This was the enthusiastic observation of Francesco Pozzobon, a skilled welder with over a decade of experience servicing and maintaining welding machines and torches, when describing our latest product.
One of the first things Pozzobon noticed was the non-slip, dragon-scale-like design of the triangular handle.
This design is particularly beneficial for welders who often work in narrow spaces and unusual positions.

The handle is made using a double injection mould with a plastic base and rubber over-moulding for a secure grip. Monica Piovan, Trafimet R&D Manager, explained that the triangular shape ensures a firmer grip compared to circular designs. It also helps welders maintain the torch's orientation without needing to look.
We accomplished this by optimising the handle length to match the operator's hand size, reducing wrist and arm strain. The handle's tapered shape widens at the rear, similar to an axe handle, preventing the torch from slipping forward. The front includes a button seat that prevents forward slipping, similar to the design of a firefighter’s hose.

Pozzobon also shared with us that the button is conveniently positioned and requires a firm push to prevent accidental activation. “I can press it normally with either one or two fingers, whether I’m wearing thin or thick gloves.”

Finnish Design Made with Italian Craftsmanship

Our ERGOPLUS MIG torch represents a fusion of Finnish design and Italian craftsmanship.

According to Eetu Kivioja, Commercial Product Manager, Torches at Kemppi Oy and Trafimet, “Its reliability and cost-effectiveness make it an appealing solution from practical and economic standpoints. This redesign balances ergonomic design with high welding performance.”

We’re happy the outcome has met Pozzobon’s high criteria for his ideal MIG torch, which he says should be “lightweight, comfortable to grip, flexible, and able to follow the movements of my arm and wrist. Most importantly, I don’t want it heating my hand, even during high-current or prolonged welding.”

The ERGOPLUS torch remains cool even during high-amperage or long welding sessions, making it comfortable to use for extended periods. The coolness is due to materials with high thermal conductivity used in the torch head and contact tip, enhancing wire smoothness and performance.

We also relocated the torch body block, the hottest part, away from the hand to prevent heat transfer to the operator. Additionally, we increased the diameter of the cooling liquid passages to ensure a greater flow rate, effectively maintaining lower temperatures and improving overall torch performance.

For Pozzobon, the ERGOPLUS MIG torch significantly impacts the final welding result, which is fundamental. “Its excellent gas protection, lightweight design, and ability to stay cool during use allow me to work comfortably for long periods without interruption. This means I can start and finish my work smoothly without wrist pain or overheating issues, leading to better overall weld quality.”

“The grip is comfortable and easy to hold, even with slippery or dirty gloves. The weight is evenly balanced, preventing wrist fatigue and allows for smooth directional changes and efficient welding” - Francesco Pozzobon

Innovative Features for Tight Spaces

Another notable feature is the ball joint, which allows for much tighter angles compared to a classic torch, making it ideal for tight spaces. “The first ball joint rotates, and the second provides even greater inclination, enhancing flexibility,” observed Pozzobon.

Corrado Di Giovanni, Trafimet’s R&D Technology Manager, said this innovation emerged following the redesign. “The change lightened the torch's front weight and enhanced operator comfort. This new joint also secures the cable harness with a more durable cover, ensuring long-lasting performance.”

We have also introduced a new IP67-rated micro-switch button tested for a million activations, replacing the previous mechanical button. Additionally, the water hoses were upgraded to rubber materials for better durability and heat resistance, with a design that avoids throttling to ensure consistent water flow.

Award-Winning Design

Several ergonomic changes were made compared to our previous model, such as reducing the torch body by about 40% and adding a pistol grip. These changes led to us winning the Red Dot Design Award 2023, which recognises products that excel in aesthetics, innovation, and functionality.

Pozzobon described the pistol grip accessory as incredibly user-friendly, especially for long, continuous welds. “This grip is advantageous for internal or awkward spots, providing stability and ease of movement. It also allows the cable bundle to rest on my arm, maintaining a comfortable wrist position.”

The pistol grip, included with each of our torch kits, lets welders choose their preferred grip based on the task. Depending on the welding position, the pistol grip can reduce operator effort by up to 64% because it changes the shoulder and elbow position.