The Welder's Digital Twin: digitizing the real production experience with Seabery Welding PRO

Industry 4.0 is moving towards a more efficient, connected and personalized production model. In this scenario, technologies such as digital twins not only transform machines or processes, but also people. The digitization of the operator and processes, especially in professions as technical as welding, opens a new dimension of analysis, training and quality control.

At Seabery, we have put this vision into practice with Seabery Welding PRO, the first program capable of creating a digital twin of the welder, adapted not to a standard or generic environment, but to the real workpieces that each company needs to weld, respecting every technical detail of its procedures (WPS).

Beyond the simulator: digitization of real practice

What sets Seabery Welding PRO apart is its ability to fully customize the simulation experience according to the real needs of the industrial customer. Starting from the actual metal workpiece, the Seabery team digitizes and parameterizes it so that it can be trained on the simulator with full fidelity, including:

Type and geometry of the workpiece.
Welding position.
Base material and consumables.
Technical parameters defined in the WPS (amperage, speed, angles, etc.).

The result is an accurate virtual version of a critical in-plant welding operation, integrated within a safe, repeatable and measurable environment. This digitization allows operators to practice exactly what they need to do in production, without consuming material or compromising the quality of the final workpiece.

A complete digital twin: operator + process + workpiece

Thanks to Welding PRO, a digital ecosystem is generated that links three key elements:

The welder – whose movements, angles, speed and technique are recorded in real time to create his digital profile.
The WPS – digitized and integrated within the simulator, ensuring that every parameter is aligned with production standards.
The actual workpiece – scanned and recreated in augmented reality so that training has a direct and useful impact on the working environment.

This allows full traceability of the simulated welding process, with objective data on each operator’s performance under specific, real-world conditions.

Real application cases

Companies in sectors such as automotive, energy, defense, shipbuilding, rail and aerospace are already applying this technology to:

Digitize critical welding procedures.
Train welders before delicate interventions.
Approve technical personnel based on measurable data.
Improve the quality and traceability of their operations.

From workshop to data, and from data to improvement

With Welding PRO, Seabery has gone a step further in the digitization of welding: it is not just about training, but about digitally replicating the real context of the work, including the workpiece, the procedure and the operator’s execution. It is a solution that connects the physical world of the production line with the digital world of data, efficiency and continuous improvement.

Welding PRO increases effective practice time through advanced simulation, accelerating welder learning by up to 33% with no preparation or clean-up required. In addition, it reduces quality issues, guarantees delivery times and offers a completely safe and risk-free training environment.