Wireless Multi-Channel Tool Holder Series for Friction Stir Welding
The FSW Instrumented Tool Holder

MegaStir is now offering a patent pending instrumented tool holder and telemetry system to upgrade milling or routing machines with FSW capability.  The tool holder provides high-speed process sampling of customer-selected channels for either tool temperature, z-axis load, or tool torque for maximum control for the friction stir welding process.  The system can also be set up with analog outputs for integrated machine control using force or temperature control algorithms.


fsw instrumented tool holder

• Wireless telemetry system with load, temperature, and torque measurement capability.

• Easy to use “nodes” that are fully rechargeable and connect wirelessly to a USB receiver.

• Can be used as a stand-alone device or simultaneously with a PC using USB interface for added utility.

• Up to 8 analog outputs for PID control (including output replicates).



Spindle taper CAT 40, CAT 50, HSK
Load capability 6,000 lbf (26.6kN) max
Maximum spindle speed 4,000 RPM
Wireless frequency 2.4 GHz IEEE 802.14.4-compliant
Analog output 8 channel analog outputs (0-3vDC)
Temperature sample rates 64 hertz
Load sample rates 512 hertz
Tool shank size 25 mm diameter
tool holder kit
fsw instrumented tool holder kit

MegaStir offers bundle kits that include up to 7 pin tools, tool holder, case, and components for FSW process monitoring, or process control integration.