Varicon - Engineering Solutions

Vrhovec 119, 10000 Zagreb, Croatia 10019

+385 98 176 7122

info@varicon.hr

Welcome to Varicon Engineering Solutions, your trusted partner in comprehensive mechanical engineering services.

About

about varicon

Welcome to Varicon Engineering Solutions, your trusted partner in comprehensive mechanical engineering services.

We specialize in Welding, Technologies, Manufacturing, Materials, Testing, Research and Development, and Engineering Simulations, offering tailored solutions to meet your project needs.

Our expertise includes Welding Coordination and Consulting for the companies, Supervision and Inspection, implementation of Welding Technologies, and full support for Welding Projects.

We offer Optimization of existing mechanical parts and structures—covering Design, Manufacturing Processes, Material Selection, and performance enhancement—to improve durability, efficiency, and cost-effectiveness while ensuring compliance with industry standards and project requirements.

We deliver innovative Research and Development for industrial products and machinery, providing complete Turnkey Solutions customized to meet client specifications. This includes detailed CAD Design, CAE Simulations and Testing. Our approaches are designed to improve performance, structural life, and operational efficiency, fostering technological progress and helping our clients maintain a competitive advantage.

Additionally, we provide extensive Materials Testing and structural measurements, as well as Non-destructive evaluation, Failure Analysis, and Quality Assurance services to ensure the integrity, safety, and performance of your engineering components and structures.

Committed to delivering high-quality, cost-effective engineering solutions, our mission is to leverage the latest technology, cutting-edge equipment, extensive knowledge, accumulated expertise, and fruitful collaborations with leading industry, research, and academic partners. By doing so, we aim to help our clients achieve their goals efficiently, reliably, and with competitive advantage in a rapidly evolving technological landscape.

Our Services

Solution for Industries

services: WELDING

Our comprehensive services in welding include:

Welding Coordination / Supervision / Inspection:

Welding coordination in accordance with EN ISO 14731
Welding supervision in all project phases
Welding inspection (IWI-C inspector level)
Implementation and compliance with welding quality systems per EN ISO 3834
Implementation and compliance with EN 1090 for structural steel and aluminum fabrication
Ensuring compliance with EN 15085 standards for railway vehicle welding processes
Qualification of welders and welding procedures, including Welding Procedure Qualification Records (WPQR)
Preparation and management of Welding Procedure Specifications (WPS) and associated documentation
Training of welders and brazing personnel covering theory, practical techniques, safety, standards, and certification
Non-Destructive Testing (NDT) and Destructive Testing (DT) services for quality assurance

Welding Projects:

Documentation, planning, and management of complete welding projects
Expert consulting on welded structures, including design, inspection, and process optimization
Implementation of new welding or soldering/brazing technologies or adaptation of existing methods
Definition and planning of welding tasks for projects, including selection of welded joints, documentation, and calculations
Design and drafting of metal structures in 3D and 2D CAD formats
Ensuring conformity with EN, ISO, ASME, and other relevant standards
Additional specialized services tailored to specific project requirements

Welding Research & Development:

R&D of advanced specialized welding techniques and processes
Research on new materials and their weldability
Process optimization and automation integration
Simulations for analyzing residual stresses and structural distortions, and techniques to minimize and control these effects
Defect prevention and quality assurance methods
Experimental testing, validation, and simulations
Collaborations with research institutions and industry partners to foster technological advancements and share knowledge in welding science and engineering

We are committed to delivering reliable, efficient, and high-quality welding solutions tailored to your specific needs.

SERVICES: TECHNOLOGIES

Our comprehensive services in technologies include:

Production Technologies:

Evaluation and consulting for defining optimal production technologies and improving product properties
Optimization of machine parts and entire structures from a technological perspective
Evaluation, process optimization, and expert consulting on manufacturing methods
Machining and subtractive manufacturing processes
Welding technology, including process selection and quality assurance
Additive manufacturing solutions for complex and innovative components
Reparation and refurbishment processes to extend component lifespan
Production management and execution in accordance with client specifications and agreements

Properties Improvement Technologies:

Defining appropriate heat treatments for materials and products to achieve desired properties
Establishing post-welding treatments to enhance structural integrity
Post-Weld Heat Treatment (PWHT) for stress relief and improved durability
Vibratory Stress Relief (VSR) to reduce residual stresses in components
Peening processes to improve surface hardness and fatigue life
Overlay welding, coatings, and protective treatments for corrosion and wear resistance
Additional specialized services tailored to specific project requirements

With a focus on delivering innovative and reliable technological solutions, we strive to help clients achieve optimal manufacturing quality and efficiency across diverse industries.

SERVICES: MATERIALS

Our services in materials include:

Optimization of machine parts and complete structures through appropriate materials selection
Definition of materials based on operational requirements, including working conditions, loads, and desired lifespan
Selection of materials considering manufacturing technologies and processing capabilities, such as weldability and machinability
Production of machine parts utilizing selected materials for optimal performance

Metalllic Materials:

High-strength structural steels with Rp0.2 > 690 MPa
Abrasion-resistant steels for wear-critical applications
Stainless steels (including austenitic, martensitic, and other types)
Maraging steels and ultra-high-strength alloys with Rp0.2 approximately 2000 MPa
Tool steels engineered for manufacturing and tooling applications
Steels and other metals processed through quenching, tempering, or case hardening techniques
Superalloys
Metallic materials tailored for specific project requirements

Non-Metallic Materials:

Technical ceramics such as Alumina (Al₂O₃) and Silicon Carbide (SiC) for high-performance applications
Polymers suited for various industrial uses
Aramid fibers for high-strength, lightweight reinforcement
Composite materials developed according to particular structural or functional demands

Our materials services encompass expert consulting on material selection, optimization of machine parts, and the manufacturing of complete components using carefully chosen materials to meet specific performance requirements.

By collaborating with top material suppliers, we have the capability to procure various grades of metallic and non-metallic materials to meet project specifications.

SERVICES: TESTING OF MATERIALS AND COMPONENTS

Our services in testing of materials, machine components, structures and welds include:

Assessment of the mechanical and functional properties of materials, machine components, structures and welds.
Development of test plans, specimen selection, standards adherence, test execution, and results analysis (testing consulting)
Manufacturing of test specimens according to specific testing standards and project specifications
Execution of tests in accordance with EN, ISO, ASTM, and other relevant standards, as agreed upon

Monotonic Testing:

Static tensile testing on standard or miniature specimens, with optional Digital Image Correlation (DIC)
Bending tests to evaluate flexural strength and behavior
Charpy impact tests to assess material toughness
Hardness testing using Vickers, Brinell, and Rockwell methods
Testing in accordance with Welding Procedure Qualification Record (WPQR)
Additional testing tailored to specific project or material needs

Fracture Mechanics and Fatigue Testing:

Fracture toughness testing following ASTM E1820, ASTM E399 standards
Crack growth assessment based on ASTM E647
Fatigue testing for low-cycle fatigue (LCF), high-cycle fatigue (HCF), and structural life evaluation
Custom fatigue and fracture testing as per client-specific requirements

Macro/Microscopic Analysis:

Macroscopic and microscopic examination of material microstructure and features
Chemical analyses of metals, polymers, ceramics, and composites
Metallography and fractography studies for failure analysis
Imaging and microstructure characterization using optical microscopy, SEM, and EDS
Preparation of samples for detailed analysis
Additional testing and analysis tailored to specific material or structural investigations

Structural Testing:

Residual stress measurement through different methodologies
Strain gauge measurements for deformation and stress analysis
Structural response measurements utilizing Wi-Fi dial gauges, load cells and other sensors
Custom structural assessments and testing based on project requirements

We can deliver a wide range of testing services utilizing our own in-house equipment, complemented by partnerships with prominent domestic and international industrial firms and scientific research organizations.

SERVICES: R&d, PRODUCT DEVELOPMENT AND SIMULATIONS

Our comprehensive services in R&D, product development and simulations include:

R&D of Products:

Complete development of industrial products and machinery tailored to client specifications
Design of products across various complexity levels and applications
Integration of mechanical elements, hydraulics, electrics, and control systems
End-to-end R&D cycle, including specifications, conceptual design, detailed design, simulations, documentation, test planning, production, and commissioning
Turnkey R&D solutions providing a fully operational system from concept to deployment

Design and Consulting:

Standalone design services, including 3D modeling, 2D documentation
Customized services tailored to specific client needs

Expert technical consulting and advisory services
Development of detailed technological documentation and specifications
Creation of operational instructions and user manuals

Simulations:

Performing Computer-Aided Engineering (CAE) through numerical simulations and engineering calculations to optimize designs
Structural static simulations (linear and non-linear analysis)
Structural dynamic simulations, including modal analysis and vibrations
Fatigue analysis based on S-N (stress-life) and E-N (strain-life) approaches
Thermal and thermo-mechanical analyses
Material data and curve generation from experimental results or databases
Geometry and structural optimization
Custom simulations and analyses as per client agreements
Design and calculation of welded connections in accordance with EN 1090 and Eurocode 3
Pipeline calculations and assessments

We provide comprehensive R&D and product development services, from concept to prototyping, tailored to client needs. Our offerings include design, 3D modeling, documentation, and simulations to optimize performance. With expert technology support, we deliver efficient, reliable, and market-ready industrial solutions.

Welding and additive manufacturing simulations

As an exclusive partner for Croatia and Slovenia, Varicon presents the heatshape, simulation software for Welding, Heat Treatment and Additive Manufacturing.

This approach applies to welding processes in metal structures where unwanted deformations are a concern. It allows for the virtual simulation of structural welding, regardless of complexity, to identify the optimal production strategy. By replacing costly physical testing on actual components, the simulation of thermal processes offers a cost-effective solution, resulting in substantial savings while ensuring accurate assessment and process optimization.

The software capabilities:

simulation of welding processes on real structures, of varying degrees of complexity and dimensions
simulation of various welding/thermal processes (MIG, TIG, laser, brazing, etc.)
adjustment of welding parameters and optimization of the sequence of passes with the aim of obtaining the most favorable deformation behavior of the structure
adjustment of clamping and workpiece support
the obtained results: temperature distribution, deformations, residual stresses, hardness, microstructure
application of the obtained results for the needs of real production
in addition to welding, simulation of other thermal processes (additive manufacturing, heat treatment)

The benefits of applying the software in production:

elimination of expensive physical testing
reduction or elimination of reworks / straightening on deformed welded assemblies (especially important for thin-walled structures and materials that are unsuitable for thermal straightening)
the ability to determine residual stresses. Although generally neglected in all phases of product development, it is extremely important for exploitation, especially for fatigue-loaded structures.
suitability for defining Post-Weld Heat Treatments (annealing, etc.)
the software is intended for manufacturing companies, this is essentially a technological and not a design tool for optimizing production
very competitive price

In addition to the heatshape software solution itself, we also offer a complete service for evaluating welded structures with the aim of optimizing their production.

More to be found on the official website:

www.heatshape.io

OUR CLIENTS AND PARTNERS

Latest Projects

Solution for Industries

services: WELDING PROJECT, CONSULTING AND SUPERVISION

CLIENT: TŽV GREDELJ (GREDELJ ROLLING STOCK COMPANY)

Project included:

Managed welding-related aspects of several major Rolling Stock projects, ensuring efficiency and adherence to EN 15085, EN ISO 3834 and other strict quality standards, and project timelines while working closely with project stakeholders
Supervised the welding of Rolling Stock key components (Bogies, Wagon Frames etc.), from initial fabrication to final acceptance, decreasing repairs and improving quality
Upgraded and standardized welding technology and processes, resulting in weld quality improvement and decrease in rework, leading to production optimization
Training, certification, and practical testing of welders to improve team skills and deliver better project results

SERVICES: WELDING COORDINATION

CLIENT: KONČAR GENERATORS AND MOTORS

Project included:

Coordination of all welding and brazing operations in accordance with EN ISO 14731, ensuring adherence to relevant welding, brazing and quality standards
Ensuring the qualification of welders (WQTC), brazing personnel (BQTC), welding procedures (WPQR) and brazing procedures (BPQR)
Development and management of Welding Procedure Specifications (WPS), Brazing Procedure Specifications (BPS), and related documentation
Training of welders and brazing personnel, covering theory, practical skills, safety protocols, standards, and certification processes

Contact us

Solution for Industries

Contact us using this form and let's start working together today.