In the last 50 years, a revolution has unfolded in the professional power tool market as corded tools used for drilling, grinding, sawing, driving and lighting have given way to cordless versions, providing convenient and powerful solutions for skilled trades in the field. It was only a logical step then for an innovative company like Fronius to develop a true professional-grade cordless welding system. In 2013, it was introduced to the market with the Accupocket 150 professional-grade cordless stick welding solution.
Fast forward to 2026, and the second-generation cordless stick and TIG welding solution, the Ignis Battery 150/750, is setting the standard for professional cordless welding solutions. This new standard in cordless welding has a new name, new capabilities and 90 percent more battery capacity.
Critical performance
As with any cordless tool, the range of target applications is broad, but the initial focus was on welding professionals and skilled workers. The system had to meet some essential requirements while keeping the professionals in mind. For one, the package had to be lightweight and easy to transport. Coming in at under 27 lbs., it is the lightest machine with a 750-Wh battery on the market.
Arc performance is critical, so the system ensures excellent performance on typical electrodes like 6010 and 7018 and offers features such as hot start and stick-pulse for out-of-position welding. A dedicated cellulose mode (6010) and stick mode (7018) provide engine-drive performance without the hassle. The machine has full-size connections preferred by professionals for the electrode holder and ground cable, so it interchanges with the rest of the Fronius equipment in the shop.
The charger is a separate device that is lightweight and compact. An important feature is the true hybrid mode where the user can plug in to a 120-V, 15-amp circuit for charging and welding at the same time. The integrated battery makes this possible by eliminating swaps in the field and the need to carry multiple batteries. The 750-Wh battery has nearly double the life of the 400-Wh battery in the Accupocket 150 predecessor.
The Ignis Battery also has nearly double the battery life of today’s competitors. Real-world testing results showed it has the capability to weld at least 12 sticks of 1/8-in. 6010, 14 in. at 88 amps or 10 sticks of 1/8-in. 7018 14 in. at 120 amps. The maximum rod count is 31 pieces of 3/32-in. 6010.
Market feedback
Fronius is confident the new system will meet the expectations of field welders, whether they are putting in a new sprinkler main pipe or welding some structural steel brackets. They can ditch the long, heavy cables and end the search for places to plug in their machine.
In early 2024, as work continued on the development of the Ignis Battery, customer feedback for market needs was critical. Visits were made to several existing customers to talk about what is needed in the field from pipefitters and sprinkler fitters. Fronius learned that if the machine could weld a 6-in. schedule 40 pipe on a single charge, with power in reserve, it would be a home run. Pipefitters choose Fronius machines for their portability, arc performance and ability to weld in hybrid mode.
The next challenge was to offer a solution that was below 30 lbs. and had enough battery for a full 6-in. schedule 40 pipe with reserve to fit-up the next section. The increase from a 400-Wh to 750-Wh battery, while only adding 2 lbs. of weight in the same small package, set the new standard for cordless capability when welding pipe in the field. The new machine is truly meant to be the go-to tool for all field pipe welding tasks.
At the zoo
While the experience working with pipefitters was enjoyable and helped bridge the gap for a needed welding solution in the field, a more interesting project was for the Saint Louis Zoo, which contacted Fronius about a cordless welding solution for welding some structural steel.
This led to another project that involved welding in a remote area of Madagascar at the Parc Ivoloina Zoological Park. The zoo plays a critical role in research and educational functions while being a sanctuary for animals that are protected and previously held illegally as pets.
When an important quarantine enclosure at the zoo had to be repaired and reinforced, this task became a major challenge. There was no way of completing the work without welding, but how could the workers weld in a location that has no power lines and no roads or tracks for vehicular access?
Derek Strunk, a construction manager at the zoo in St. Louis who traveled to Madagascar, says the portability factor was a major bonus.
“The ability to simply toss the device into a golf cart and drive to the worksite without any cables or generators has increased efficiency and reduced noise pollution for animals and visitors,” he says.
The experience gained from these projects confirmed the Fronius decision to further expand its range of battery-powered welding machines. It is clear just how crucial mobile welding technology is under genuine extreme conditions, especially in remote locations like the nature reserves of Madagascar.
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