ARQ – Underwater welding unit

Project Information

As a response to the massive physical strain placed on commercial divers, I developed this advanced welding system during my thesis project. My objective was to integrate heavy duty, high speed continuous wire feed welding into the deep ocean environment.

During my research, I identified that divers are relying on traditional manual stick welding. This method is slow and exhausting because it requires the operator to constantly pause their workflow to reload single consumable electrodes. The introduction of continuous wire would drastically speed up large scale infrastructure repairs, but a massive15 kilogram wire spool and the accompanying feeding motors are far too big and heavy for a human operator to physically carry underwater. My goal was to completely reimagine this workflow, taking the physical weight off the diver while providing them with an incredibly precise, high-performance tool.

Methods

To truly understand the extreme realities of the underwater environment, my design process began with a field trip to NYD in Oslo. Conducting first hand, on site research alongside experienced commercial divers provided invaluable insights into the daily physical demands and operational constraints of the profession. This direct exposure formed the solid foundation for my entire design approach.

To solve the complex ergonomic challenges identified during this research, my process relied heavily on physical prototyping. I built full scale physical models of the unit as well as the torch to accurately evaluate dimensions, proportion, ergonomics and interactions. Testing was conducted while wearing thick three finger neoprene drysuit gloves to simulate real working conditions and evaluate the diver's grip and reach.

To define the visual language, I utilized AI for rapid shape exploration across both the main unit and the handheld torch. I then 3D printed 1:8 scale physical models to evaluate different structural frames in real space. This allowed me to rigorously compare bulky, purely geometric industrial aesthetics against more fluid chassis designs before committing to the final form.

Result

The final concept is a two-part system that completely removes the physical burden of heavy machinery from the human operator. The primary component is an independent subsea unit that safely houses the dense wire spool and feeding drive. By operating an intuitive, thumb trigger on the main handle rail, the diver controls an active pneumatic buoyancy system. This allows them to instantly adjust the internal air volume, transforming the massive hub into a weightless companion that glides effortlessly alongside them. Because the trigger mechanism relies only on the thumb, the diver maintains a fully secure, locked grip on the machine at all times.

The diver actual welding tool is the lightweight handheld torch. Connected to the main unit by a flexible whip, this tool was ergonomically tailored specifically for the severe tactile restrictions of bulky drysuit gloves. Crucially, the torch features an extendable neck. This adjustable barrel allows the diver to change the length of the tool on the fly, providing critical reach and versatility when facing different working scenarios. 

Aesthetically, the entire system is guided by two core pillars: Honest Architecture and Technical Elegance. Deep, geometric cutouts in the main exoskeleton frame provide the surface crew with fast, unobstructed access to the internal components. Meanwhile, the refined touchpoints ensure safe and intuitive operation for the diver. Ultimately, this system introduces a new era of capability to the subsea environment, making the incredibly demanding profession of commercial diving easier, highly convenient, and exceptionally safe.