The state-owned enterprise VOP CZ is developing another strategic capability in the European defense industry. After obtaining the demanding DIN 2303 / Q3 certification, which is required for welding German-made military equipment, the company has joined a project to weld armored cabins for KNDS Deutschland. The contract builds on VOP CZ’s previous experience with Pandur vehicles and NIMR cabins and may pave the way for further projects in the German defense market.

Video: VOP CZ Welds Armored Cabins for KNDS, Entering the Top Tier of Military Welding / CZ DEFENCE

According to Pavla Ungrová, commercial director of the state-owned enterprise VOP CZ, the project to weld armored cabins for KNDS was initiated following a direct request from a German partner. The company’s previous experience in the production and repair of military equipment played an important role. “The cab welding project arose from a request by KNDS, which approached us based on our experience with manufacturing NIMR cabs and on various projects we’ve had with Pandurs,” said Ungrová.

The essence of the project is the production of armored cabins designed for vehicles on Iveco chassis, which are supplied to the German Bundeswehr. This is not ordinary welding of steel structures, but highly specialized work with armored steel, which places extraordinary demands on worker qualifications, technological processes, and quality control. In order for VOP CZ to participate in the project, it had to undergo the DIN 2303 / Q3 certification process, which included an audit of welding processes, the production of test weldments, and their ballistic testing at certified testing facilities of the German Army.

The VOP CZ welders themselves also underwent rigorous training. Selected employees traveled to Germany, where they completed training and exams at a welding school. “Our welders had to travel to Germany to attend a welding school and pass exams there so that, upon successful completion, they could obtain Q3 certification, which allows them to weld truly demanding welds and joints in armored steel,” explained Ungrová. VOP CZ currently has seventeen welders who have successfully completed this process.

The welding of armored cabins is both technologically and physically more demanding than standard work with softer materials. Armor has specific properties; during welding, these material characteristics – including magnetic phenomena – can manifest, and the requirements for the final quality of the welds are also significantly higher. “The armor has its own specific properties, so the welding itself is more complex. The customer’s requirement is that the welds really have to be top-notch,” said Ungrová. In addition to the welding itself, workers therefore spend a considerable amount of time preparing, finishing, and grinding the welds.

VOP CZ does not limit itself to just welding operations in this project. According to Pavla Ungrová, one of the company’s advantages is that the welders also perform metalworking tasks. While in Germany these tasks are often divided among multiple professions, at VOP CZ, workers must handle a broader range of tasks. “Another difference between cab production in Germany and here at VOP is that our welders also have to do metalworking,” explained Ungrová. It is precisely this versatility that can be an advantage for the company, but at the same time, it places higher demands on the workers’ qualifications and experience.

The project also required modifications to the production facilities. VOP CZ set aside a separate hall for welding armored cabins, which is designed specifically for this type of production. The transfer of know-how from KNDS also included specialized jigs used for handling and the welding process itself. The company further equipped the hall with devices such as positioners. According to Ungrová, in its current configuration, the space is intended exclusively for this project, as the layout of the jigs and equipment makes it practically impossible to manufacture other components at the same time.

Manufacturing a single cabin is time-consuming. Based on experience from Germany, the entire process – including additional operations such as sandblasting and painting – can take up to 35 days. However, VOP CZ plans to shift part of this work to robotic welding in the future. “We would like to shorten that time in the future, thanks in part to robotization,” says Pavla Ungrová. Robots are expected to be tasked primarily with larger assemblies and parts where the technological process allows for it. At the same time, however, she points out that not everything can be automated, and therefore the company will continue to need qualified welders.

The contract with KNDS is currently expected to include approximately 130 armored cabins, with additional options and potential expansion of the collaboration also on the table. If the project is successfully completed, it could be followed by the production of hundreds more units as well as individual parts, such as doors and other components mounted on the cabins. This is where the broader significance of the entire contract becomes apparent. For VOP CZ, this is not just a one-time production run, but a showcase project that could open doors for the company to new customers and additional programs within the European defense industry.

An important part of the project is ongoing quality control. The German partner provided VOP CZ with specifications for inspection processes, including magnetic and visual tests, measurements, and reports, which the company sends to Germany for consultation and evaluation. Prior to the start of series production, a test cabin designed for ballistic testing was also manufactured at the WTD 91 testing facility. Series production can only be approved after the quality of the welds has been confirmed and the German partner’s requirements have been met.

Obtaining Q3 certification, the ability to work with armor steel in accordance with German standards and Bundeswehr requirements, and direct cooperation with KNDS represent an important step not only for the state-owned enterprise VOP CZ itself, but also for the Czech defense industry.