Miller and Gullco Partner to Launch Miller® Hercules™ Welding Technology on Gullco Tractor at FABTECH 2025

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09/04/2025 - 01:00 PM

Joint solution integrates automation, filler metal and MIG technology to deliver high-efficiency welding for heavy industries.

APPLETON, Wis.--(BUSINESS WIRE)-- Miller Electric Mfg. LLC, a leading worldwide manufacturer of Miller brand arc welding equipment, is partnering with Gullco International to introduce Hercules, a high-deposition welding automation system engineered for high-efficiency MIG welding. The solution will make its debut at FABTECH 2025, where welders will experience how this innovation integrates automation platforms from Gullco, power sources from Miller, filler metals from Hobart® and MIG gun technology from Tregaskiss — delivering a streamlined, high-performance solution tailored for efficiency and productivity in heavy fabrication.

Hercules machine at Gullco FABTECH booth.

Hercules is a novel arc welding process first introduced by ITW in August 2022. Unlike traditional MIG welding, Hercules uses a second power supply to preheat the electrode before initiating the primary arc. This hot-wire technique, previously seen in TIG and laser welding, allows for precise control of filler metal conditions, resulting in significantly higher deposition rates and improved productivity.

Since its launch, Hercules has consistently delivered up to 30% higher deposition rates compared to MIG processes. “Hercules delivers the same high deposition rates you’d expect from tandem GMAW, twin-arc or even sub-arc welding, but without the added complexity,” says Jason Ball, Miller automation sales manager. “Multi-wire systems introduce challenges related to arc stability and wire feeding, and sub-arc often incurs additional costs due to flux handling and cleanup. Hercules achieves performance without those added headaches, providing a more straightforward and cleaner way to run high-deposition welds.”

Initially deployed in robotic applications, Hercules has proven especially effective in fixed automation environments, ideal for long, straight welds in industries such as heavy equipment, bridge and tunnel solutions. “Fixed automation is the space where Hercules is really going to shine in the welding market, and Gullco is the leader in this domain,” says Matt Kramer, automation specialist at Miller.

Gullco will debut Hercules on a fixed automation solution for the first time at FABTECH 2025 in Chicago, September 8–11. “This is a game-changing development in high-deposition welding, and we are really excited to show this to the world at FABTECH,” says Jeff Zook, president and general manager of Gullco USA. “We are seeing deposition rates in pounds per hour that compare or sometimes beat sub-arc for the same-size wire diameter with one pass. Hercules allows for multiple passes with the ease of standard MIG welding.”

Visit Gullco International and Miller at booth 15009 to experience Hercules in action, and schedule a live demo here. To explore Hercules, visit https://www.millerwelds.com/products/hercules.

About Miller

Miller Electric Mfg. LLC, headquartered in Appleton, Wisconsin, is a leading worldwide manufacturer of Miller^® brand arc welding products and is a wholly owned subsidiary of Illinois Tool Works Inc. (NYSE: ITW). For more information, visit MillerWelds.com, call 1-800-4-A-Miller (800-426-4553), email info@millerwelds.com, fax 877-327-8132, or write to Miller Electric Mfg. LLC, P.O. Box 100, Lithonia, GA 30058.

About Gullco

With over 70 years of innovation, Gullco manufactures and delivers precision mechanized welding, cutting and beveling automation systems that enhance productivity, improve safety, and ensure superior industrial weld quality.

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