MeltTools

MeltTools VISUALIZE WELDING - Visualizing welding in-process will enable technological breakthrough, ensure qu

Want to catch weld defects before they become costly repairs?Our newest article on our website breaks down exactly how w...
05/06/2026

Want to catch weld defects before they become costly repairs?

Our newest article on our website breaks down exactly how welding cameras give operators a clear, real-time view of the process zone, from a safe distance. It’s not just about a better view; it’s about measurable ROI.

Discover 6 core benefits of welding cameras, including:

🔸 Enhanced operator safety & working conditions
🔸 Immediate defect detection & correction
🔸 Automated inspection & process control
🔸 Faster setup & accurate positioning

We even included step-by-step implementation guides so you can get the most out of your investment efficiently.

You’ve decided to leverage welding AI, a smart move that can drastically improve weld quality, reduce scrap and provide ...
03/25/2026

You’ve decided to leverage welding AI, a smart move that can drastically improve weld quality, reduce scrap and provide real-time welding videos. But what does the implementation process actually look like?

Our latest online article outlines the essential stages of welding AI implementation, covering:

🔸Selecting appropriate system hardware
🔸Choosing the desired AI model(s)
🔸Defining a clear data strategy
🔸Establishing a realistic deployment timeline

Our welding cameras are designed to operate through the toughest of welding environments, and our MeltView® PIXI’s are n...
03/18/2026

Our welding cameras are designed to operate through the toughest of welding environments, and our MeltView® PIXI’s are not an exception.

We recently received two PIXI cameras for repair after the cameras accidentally overheated. These cameras, manufactured in 2022, have been in continuous operation on the shop floor since implementation. While their cosmetic appearance clearly showed wear from the tough environment they are in, we found their cameras could be repaired back to their original state. After some electronic replacements and quality testing, these cameras were sent back for further use.

some of our customers rely on our flagship analog cameras, such as the MeltView® DART and MIRA, for their daily weld mon...
03/10/2026

some of our customers rely on our flagship analog cameras, such as the MeltView® DART and MIRA, for their daily weld monitoring. While we transitioned to digital HD-SDI imaging to offer benefits like reduced interference and higher image quality, we have continued to support our analog camera systems by manufacturing replacement cameras and building camera systems as needed.

However, we finally encountered a significant hurdle: the camera sensors for our analog models are obsolete, and we have used all our stock. This threatened to force our analog camera customers to invest in entirely new HD-SDI camera systems, as our new technology is incompatible with the older, analog technology. As some of these customers use multiple systems throughout their factories, replacements would quickly become costly. This became a situation we were determined to avoid.

Our engineering team worked together and devised a solution: we built a new interface board with a microcontroller for our HD-SDI cameras, such as the DART2, which interprets the signals from our earlier analog camera systems, such as the original DART.

With a new interface board, these modified DART2 and MIRA3 camera sensors function as analog cameras, capable of producing similar welding images to those that our customers see with their current systems. The fact that our current DART2 and MIRA3 camera bodies are more compact than our previous models means that the replacement cameras also offer advantages in terms of space.

This solution ensures we can continue to support our foundational customers with their original camera systems, without forcing them into unnecessary expenditure on new equipment. Even as technology continues to advance, we are attentive to the needs of all our customers, no matter the camera model they have.

We had a customer looking for dual camera suitcases for onsite orbital welding. Enter the MeltTools suitcase.We designed...
03/03/2026

We had a customer looking for dual camera suitcases for onsite orbital welding. Enter the MeltTools suitcase.

We designed and built two 22” monitor display suitcases with 1080p resolution, an integrated advanced controller for easy camera adjustments, and DART2 cameras for real-time direct display monitoring. With built in electronic protection, the suitcase provides protection from electromagnetic interference and power surges. The suitcase is large enough to fit the cameras, cables, display remote and advanced controller, making transport easy and ensuring all portions of the camera system are protected.

While we have our signature designs in place for the suitcase, there is always the opportunity for customization!

Integrating camera and sensor technologies into welding education is fundamentally changing how technical skills are tau...
02/24/2026

Integrating camera and sensor technologies into welding education is fundamentally changing how technical skills are taught, acquired, and perfected. These tools effectively address long-standing challenges in welding instruction while unlocking new avenues for learning insight and skill retention.

Our latest article details the senses, improvable skills and benefits associated with implementing a welding camera system. Make sure to check it out on our website!

Working with limited space but want to monitor and control two cameras from one work station? Maybe a custom solution is...
01/13/2026

Working with limited space but want to monitor and control two cameras from one work station? Maybe a custom solution is the best fit!

We had a customer who reached out looking for monitoring subarc welding. One camera needed to watch the weld itself, while the second monitored a larger area of the welding cell for machine alignment, with the potential to integrate a laser for even greater precision. Their main obstacle was the lack of space for multiple displays to monitor and control both camera feeds. They requested a custom setup to simplify monitoring and control for their operators.

Our off-the-shelf configurations of the MeltView® PIXI and PROWatch industrial cameras suited their welding needs. The PIXI, with its integrated cooling, could provide a close-up, damage-free view of the weld even under extensive use. The PROWatch offered wide-area imaging of the welding cell and was designed for simple direct-display functionality. Both cameras were exactly what the customer was looking for; all that needed to be done was manufacturing a display and control system that matched their size constraints.

We engineered and built a custom display and control box that could be mounted conveniently within the welding cell. This box streamlines the operator’s workflow, providing easy access to switch the monitor view between the PIXI and PROWatch cameras and adjust camera menu settings as needed. Additionally, the display box allows for the integration of a laser, which can be used to aid in machine alignment. By centralizing control of the two cameras and the laser in one area, operators can modify the system quickly and easily, reducing machine downtime between necessary adjustments.

We recently received one of our MeltView® DART cameras for repair, and the issue was immediately apparent: the camera wa...
12/15/2025

We recently received one of our MeltView® DART cameras for repair, and the issue was immediately apparent: the camera was covered in oil. Our customer made the right call by sending it in before further damage could occur to the camera. While this was a first for our team, we handled it without missing a beat. After a thorough wash and some parts replacement, the camera passed testing and was shipped back to keep our customer’s operations running smoothly.

It’s situations like these that remind us why responsive support matters. No matter what comes through our doors, whether it is a camera no longer made or part of our current line, we’re ready to get equipment back in action.

Custom solutions for customer optimizationA customer approached us with a challenge: they needed to monitor orbital weld...
11/26/2025

Custom solutions for customer optimization

A customer approached us with a challenge: they needed to monitor orbital welding with two cameras simultaneously, but space was extremely limited, and they wanted a portable display where the cameras could be stored within the kit.

The MeltView® TERA checked the boxes—at just 36 x 43 x 56 mm (1.4 x 1.7 x 2.2”), it delivers direct-display 1080p HD resolution while operating as close as 2 inches (51 mm) from the weld. With integrated cooling and LED illumination, it handles temperatures up to 300°C (572°F) for extended welding operations, allowing it to be used for multiple weld passes without a break.

But finding the right cameras was only half the solution; we needed a display system that could showcase both TERA feeds while meeting their storage and protection needs. Our engineering team designed a custom 22” 1080p dual-monitor setup integrated into a rolling industrial suitcase with a built-in advanced camera controller. The large dual screen allows both cameras to be monitored simultaneously, while the integrated advanced camera controller enables operators to make any necessary adjustments in the field. When done, the cameras can be packed up in the portable case, ready for their next welding application.

When standard equipment doesn’t fit your workflow, we build what does.

A customer approached us with a challenge: they needed to control four MeltView® DART2 cameras simultaneously with a sin...
10/22/2025

A customer approached us with a challenge: they needed to control four MeltView® DART2 cameras simultaneously with a single signal output—but no standard solution existed.

Our team engineered a custom advanced camera controller that delivers exactly what they needed. This tailored system combines the video feed from four welding and/or inspection cameras into one HDMI output, enabling operators to:

✅ Observe multiple cameras on a single 16:9 HDMI monitor occupying the screen completely
✅ Adjust all camera settings from a single controller
✅ Capture critical leading / trailing views and inspection views
✅ Enhance weld quality via superior visibility

The Result?

An efficient solution that saves space and simplifies complex welding operations where multiple perspectives aren’t just helpful—they’re essential. Any combination of DART2, PIXI or PROWatch cameras can be deployed.

This is what custom engineering looks like: solving real problems that standard equipment can’t.

Address

7847 SOUTH SPRINKLE Road
Portage, MI
49002

Opening Hours

Monday 9am - 6pm
Tuesday 9am - 6pm
Wednesday 9am - 6pm
Thursday 9am - 6pm
Friday 9am - 6pm

Telephone

+12699780968

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