Miller's ArcCapture Brings the Weld Arc into High-Definition Focus

APPLETON, WI – January 12, 2026 – Miller Electric Mfg. LLC, a cornerstone of the arc welding industry, today announced the launch of its ArcCapture™ weld camera systems. The new product line is engineered to provide a crystal-clear, high-definition (1920 x 1080) view of the live welding arc, a development poised to significantly impact both vocational training and the world of industrial automation.

This move signals a strategic expansion for the Appleton-based manufacturer, pushing beyond its traditional portfolio of welding equipment into the rapidly growing market for advanced process monitoring and vision systems. With compact, easy-to-install units available in both hard-wired and Wi-Fi enabled models, ArcCapture aims to make high-tech weld visualization more accessible across the board.

A New Vision for Vocational Training

The launch comes at a critical time for skilled trades. The welding industry continues to grapple with a persistent skilled labor shortage, placing immense pressure on educational institutions to train new technicians more effectively and efficiently. Traditionally, instruction has been a hands-on but visually limited process, with instructors struggling to observe the nuanced techniques of each student in a crowded workshop.

ArcCapture directly addresses this challenge. By capturing a live feed of the weld pool, instructors can project a demonstration to an entire classroom, ensuring every student gets a perfect, front-row view of proper technique. They can also remotely monitor individual student booths, providing real-time guidance and feedback without physically crowding the workspace, which enhances both safety and instructional bandwidth.

"Being able to see the weld pool in such clarity, and share that view with an entire class simultaneously, is a game-changer for how we teach this trade," an industry educator with over two decades of experience noted. "It demystifies what's happening behind the arc. Students can immediately see the cause and effect of their movements, accelerating their learning curve dramatically."

The system's Wi-Fi model further enhances this flexibility, allowing for multi-device streaming to phones, tablets, and computers. This feature enables a more dynamic and interactive learning environment, where visual aids are not confined to a single screen. By improving the quality and efficiency of training, such technologies are seen as a vital tool in attracting new talent and closing the skills gap.

Automating Accuracy on the Factory Floor

Beyond the classroom, ArcCapture is designed to meet the rigorous demands of modern manufacturing. As industries from automotive to aerospace increasingly rely on robotic and automated welding systems, the need for precise process control and quality assurance has become paramount. The global market for related technologies, such as AI-based visual inspection for welds, was valued at over $1.6 billion in 2024 and is projected to expand at a CAGR of nearly 14% through 2033, underscoring the immense demand for advanced quality control.

Miller’s new camera systems integrate seamlessly into these automated environments. The compact units can be mounted directly onto the welding torch, a nearby fixture, or end-of-arm tooling, providing operators and quality control teams with a real-time window into the automated process. This constant visual feedback is crucial for monitoring arc stability, ensuring proper material deposition, and identifying potential defects as they happen, not after a costly production run is complete.

"In high-stakes manufacturing, visual confirmation of weld integrity in real-time isn't a luxury; it's a necessity for reducing rework and ensuring compliance," stated a specialist in automated systems. "A system that provides a clear, recordable view of every weld is an invaluable asset for root cause analysis and continuous process improvement."

By enabling operators to see what the robot sees, ArcCapture helps ensure that automated processes remain within strict parameters, ultimately boosting productivity, reducing scrap rates, and enhancing final product quality.

Inside the Arc: Technology in a Competitive Market

The market for specialized weld cameras is a competitive and technologically advanced space, with established players like Xiris Automation and Cavitar offering sophisticated systems. These systems often feature High Dynamic Range (HDR) imaging, a critical technology that allows the camera to see both the intensely bright arc and the darker surrounding metal simultaneously—a feat standard cameras cannot achieve. ArcCapture enters this market, valued at approximately $850 million in 2024 and projected to grow at a CAGR of over 7%, with a distinct strategy.

While competitors often focus heavily on high-end industrial applications with systems that can cost upwards of $15,000 to $20,000, Miller appears to be targeting a broader audience with its emphasis on portability, ease of installation, and a dual-market approach. The explicit focus on the educational sector, combined with features like Wi-Fi streaming, represents a key differentiator.

By offering a high-definition, user-friendly solution, Miller is positioning ArcCapture as an accessible entry point into advanced weld monitoring for vocational schools, smaller fabrication shops, and large-scale industrial users alike. This strategy leverages Miller's extensive distribution network and trusted brand name to penetrate a market segment that may have previously viewed weld camera technology as too complex or expensive.

A Strategic Weld in Miller's Portfolio

The launch of ArcCapture is more than just a new product; it represents a calculated strategic move for Miller Electric and its parent company, Illinois Tool Works Inc. (ITW). It diversifies Miller's offerings, moving the company into the high-growth sector of industrial vision and data systems. This aligns perfectly with ITW's overarching corporate strategy, which prioritizes customer-centric innovation and developing differentiated products that solve fundamental industry problems.

By directly addressing the twin challenges of workforce development and manufacturing quality, Miller is reinforcing its role not just as an equipment supplier, but as an integrated solutions provider for the entire welding ecosystem. With the launch of ArcCapture, Miller Electric is not just selling a new tool, but is actively shaping the future of how welding skills are taught and how quality is assured in modern manufacturing.