The gap between welded components plays a crucial role in determining weld quality, as variations in gap size can lead to issues such as incomplete penetration, incorrect heat input, or distortion. Wiresense is an innovative welding technology that addresses these challenges by using the welding wire as a sensor to measure the gap in real-time. In addition, dynamically adjusting welding parameters, Wiresense ensures optimal weld quality, particularly for thin materials and variable gaps. This thesis, developed during an internship at a leading automotive company, explores the integration of Wiresense into Body-in-White (BIW) and chassis assembly processes. BIW is a critical phase in automotive manufacturing that involves assembling the vehicle’s structural components.