COME TALK WITH THE WORLD EXPERTS IN SOLID STATE PROCESSING

Bond at FABTECH Chicago | Sept. 8–11 | Booth #B17039 with KUKA | RFSSW on a KUKA Robot!

Bond at FABTECH Chicago

Sept. 8–11 | Booth #B17039 with

KUKA RFSSW on a KUKA Robot!

Meet us at

Detroit, MI | October 6-9 | BOOTH 3651

+1 (574) 327-6730
Proud Sponsor of IFWC 2026  May 19–21 | Cambridge, England

Research & Development

Leading the Way in Friction Stir Welding Research & Development

Bond Technologies is committed to advancing Friction Stir Welding (FSW) research through close collaboration with higher learning institutions and research centers worldwide. As a dedicated partner to the R&D community, we support cutting-edge exploration in Friction Welding and Processing technologies by providing not only advanced machinery but also expert guidance and collaboration.

Our RM Series machines, including the RM7 and RM15, are designed with flexibility and power in mind, equipping researchers with the tools needed to develop new technologies. Bond remains focused on fostering innovation and supporting the next generation of technological breakthroughs in FSW.

Bond Technologies RM Series Friction Stir Welding (FSW) machines, including RM7 and RM15, designed for research and development with advanced controls, high torque, and versatile capabilities.

Advancements in FSW Research & Development

View FSW Machines for R&D Applications ⟶

Since its beginnings in the early 1990’s, FSW has been actively evolving as innovations become implementations. Some of the early welding tool designs such as the scrolled shoulder and tapered, threaded pin have endured long after the patents expired. However, increased applications of materials such as titanium and high temperature alloys drove the development of better tool materials and designs. Tool life has been increasing over time through the use of coatings and tool materials.

Evolving FSW Technologies and Innovations

In the 2000’s, Transformation Technologies, Inc (TTI) discovered the importance of rigid machine design to welding process parameters and welding tool life. Bond carries these principles forward using high precision ballscrews, linear guide rails and gearboxes to reduce deflection and backlash. Careful attention to design of machine structures with the goal of minimizing deflection has led to stronger, more capable and highly reliable machines for FSW.

Tailored Solutions for Research & Development

Understanding the diverse needs of the R&D industry, Bond offers a range of specialized machines designed to address specific challenges.

Research (RM) Series Machines

Flexible Solutions for Research & Development

The RM Series by Bond Technologies offers versatile Friction Stir Welding (FSW) machines designed specifically for research and development applications. Featuring models such as the RM7 and RM15, these machines provide the flexibility and precision needed to support cutting-edge exploration in solid-state processing. The RM Series includes advanced features like User Programmable Logic™ for developing custom control algorithms and high mechanical stiffness to ensure accurate, reliable results. Ideal for academic institutions, research centers, and industrial labs, the RM Series delivers powerful tools for advancing FSW technology and materials science.

View Research (RM) Series Machines

Friction Extrusion (FE) Machines​​

Unlocking New Material Innovations

Friction extrusion is at the forefront of material science research, using frictional heat and severe plastic deformation to transform metallic workpieces into fine-grained, high-quality metals. This process opens the door for researchers to create custom composite materials with unique properties, such as enhanced thermal and electrical conductivity, improved ductility, and superior high-temperature performance. Bond’s expanding lineup of friction extrusion systems is designed to meet the evolving needs of the R&D community.
View FE Machines

Refill Friction Stir Spot Welding (RFSSW)​ Machines

Advancing Joining Technology

Refill Friction Stir Spot Welding (RFSSW) offers research institutions a cost-effective solution for exploring new materials and high-rate automated production. Bond’s RFSSW machines deliver precise control over spindle speed, axis velocity, and force, enabling the development of strong, high-quality welds across various applications.
View RFSSW Machines

Custom & Special Purpose Machines

Innovation for Specialized Applications

Bond provides Custom Special Purpose Machines tailored for research and development in solid-state processing. These flexible, precise machines enable researchers to explore new materials and techniques, supporting advanced R&D efforts and the transition from lab discoveries to practical applications.

View Custom Machines
Bond Technologies engineer reviewing weld data on a laptop and monitor

The future of FSW Research & Development

Applications such as shipbuilding and space launch vehicles recognize FSW’s benefits for reliably joining large aluminum structures like ship decks and cryogenic fuel tanks. Recently, the automotive industry’s shift toward electrification has spurred innovations in FSW for battery trays and cryogenic cold plate modules.

The future focus of R&D is likely to produce progress in:

  • Materials
  • Process Development
  • Modeling
  • Simulation Tools
  • Intelligent Machine Controls

Advancements in FSW

Advancements in Friction Stir Welding (FSW) have been driven by the demands of working with steel and high-temperature alloys. Key areas of development include:

  • Tooling Materials: Higher forces and temperatures required for steel and other alloys have led to improvements in tooling materials to enhance durability and performance.
  • Process Control Algorithms: Evolved to increase welding speed, accommodate variations in joint geometry, and optimize other critical factors.
  • Modeling and Simulation Tools: Originally developed for academic R&D, these tools are expected to become essential resources for process engineers, aiding in the design of welding tools and setting process parameters.
  • Machine Intelligence and Software Control: As machine intelligence becomes more widely accepted, advanced software will play a crucial role in controlling the welding process, offering significant benefits for production applications of FSW.

These advancements collectively push FSW technology forward, meeting the evolving demands of modern manufacturing.

RFSSW and Advancing R&D in Joining Technologies

While frictional heat for spot welding isn’t new, Refill Friction Stir Spot Welding is set to transform aluminum lap joining in aviation and automotive applications. Ongoing R&D is advancing cycle time and joint strength, with significant improvements in tool life overcoming previous barriers to large-scale production. This progress has brought the cost per joint in line with, or even below, traditional methods like rivets and resistance spot welding.

As research explores new alloys and material combinations, the Bond RFSSW weld head is fully equipped for the challenge, with spindle speed, axis velocity, and force capabilities optimized for a wide range of applications.

View Refill Friction Stir Spot Welding (RFSSW) Machines

Friction Extrusion: Pioneering Technology for R&D and Production

Originally invented in 1991 by researchers at The Welding Institute, Friction Extrusion (FE) has been a focal point of materials research for decades, though its commercial applications were constrained by the lack of suitable equipment. Bond Technologies changed that by designing and building the first-ever purpose-built Friction Extrusion machine—currently the only FE systems on the market.

Our FE machines are invaluable for research and development, providing a platform for materials scientists to explore new alloys and processing techniques. The systems include custom tooling and fixture design, with workholding fixtures that interface seamlessly with the machine controller to ensure error-free operation. This integration is vital for R&D environments, where detecting process inconsistencies and maximizing efficiency are crucial for advancing materials science and developing new applications for FE technology.
View Friction Extrusion (FE) Machines
Bond Technologies, Friction Stir Welding, Friction Extrusion FE machine

Standing on the Shoulders of FSW Research Pioneers

Since the early days of Friction Welding and Processing, innovation has been a constant. Pioneers like Wayne Thomas, who advanced Friction Stir Welding (FSW) in the 1990s, laid a foundation for ongoing research. Bond Technologies builds on this legacy, with a team dedicated to developing new processes, machine designs, and tooling while collaborating with academic institutions worldwide. Our work supports R&D customers in exploring new ideas, which in turn helps refine our products.

Our expertise in transitioning innovations from research to value-generating production has made us a major contributor to the FSW industry. We continuously ask, “When you use frictional heat to soften metal, what can be done beneficially?” The answers have led to machines capable of friction extrusion, refill friction stir spot welding, friction deposition, and other advancements. Bond is committed to cultivating relationships within the research and development community, standing on the shoulders of great innovators to turn breakthroughs into valuable technologies that make the world a better place.
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Why Partner with Bond Technologies in Research & Development?

Expertise in Friction Welding and Processing

With decades of experience in friction welding technologies, Bond Technologies brings deep industry knowledge and innovative solutions to support cutting-edge research and development.

Collaborative Approach

We work closely with research institutions and laboratories, fostering partnerships that drive technological advancements and enhance our products through shared insights and expertise.

Tailored Solutions for R&D

Our machines, including the RM Series, are specifically designed to meet the diverse needs of research, offering features like User Programmable Logic™ and high mechanical stiffness to ensure precise and reliable results.

Seamless Transition from Research to Production

Bond specializes in helping customers move from the R&D phase to full-scale production, providing the tools and expertise to turn innovative ideas into practical, value-generating solutions.

Partner with Bond for Cutting-Edge R&D in Friction Welding and Processing

Contact Bond Technologies to explore collaboration opportunities in Friction Welding and Processing research or to learn more about our versatile RM Series machines. Let’s work together to push the boundaries of innovation.