Aluminum’s high thermal conductivity and deformation tendency posed significant challenges, especially for long, continuous butt welds. To address this, we conducted detailed welding simulations using CFD techniques, breaking the 4.5-meter weld into 15 sections to manage heat dissipation and prevent profile distortion. The fixture design included modular components weighing up to 1.5 tons for each of the four welding stages. This approach minimized deformation, reduced production time, and achieved high repeatability. Additionally, the square-shaped canister’s C-profile mating surfaces required precise alignment with flat plates, where we used jig-mounted clamps for stable positioning during welding. This solution delivered cost efficiency and enhanced the client’s production throughput.