The Miller Maxstar 161 STL TIG and Stick Welder takes the dual-process welder to a new level. It replaces the legendary Maxstar 150 as part of Miller Electric’s next-generation lineup of professional welding equipment. The cutting-edge design combines two welders into one machine: the precision TIG and the rugged stick welders. Compact and light, the Maxstar 161 is recognized as the gold standard for dual-process welders.
Miller’s new iteration of this portable welder offers smooth TIG arc starts, a built-in gas solenoid and gas valve for easy setup, and dependable welding output across a wide amperage range. Ideal for welding aluminum, mild steel, and other thin materials, the Maxstar 161 STL makes it easy to start welding confidently — even on difficult-to-run electrodes. Pair it with a TIG torch, foot pedal, stick electrode holder, and quality power cables to achieve precise control for critical welds.
Designed by Miller Electric, this AC/DC TIG-Stick machine runs on 240 V power and offers a solid duty cycle for serious performance in any industry. Miller welding products are known for reliability, energy efficiency, and advanced features that deliver professional-grade weld quality.
Miller Maxstar 161 Features and Benefits
The new Miller Maxstar 161 welders have a digital interface and a greater amperage range than their predecessor, the Maxstar 150 units. Machine setup is done in three easy steps: press the menu button to select your process, then hold the menu button for 1 second to access the user menu. The last step is turning the encoder to adjust your selected parameter.
The Maxstar 161 STL units are DC only and will not TIG weld aluminum. This package does NOT include a TIG torch.
New Features
• Digital meter interface • Auto-line 120V and 240V power cords • Pulse feature on STH models only • Upgraded shoulder strap and handle • Added space inside the X-Case
Quick Specs
• Stick Amperage Range: 120V – 20-90A | 240V – 20-160A • TIG Amperage Range: 120V – 5-130A | 240V – 5-160A • Material Thickness: .020 – 3/16 Steel | 5/32″ Electrodes • Duty Cycle: 120V – 30% at 90A | 240V – 20% at 160 amps • Dims: 10.3 H x 5.6 W x 13.5 D • Weight: 13lbs
Includes
• Maxstar 161 STL power source • 6.5ft 120V and 240V power cords • 13ft Stick electrode holder and 25mm dinse connector • 10ft Work clamp • Air-cooled TIG torch connector (195234) • Shoulder strap and handle
Looking For Your Next Miller Welding Project?
Experienced welders and anyone just starting out will appreciate the Miller Maxstar 161 STL TIG and Stick Welder because of its versatility. High-quality Miller welders are popular for their rugged design and ease of use.
Check out our selection of welding gear, featuring other great Miller welders — the perfect partner for your next project. Want to see more? Visit Welding Supplies from IOC to explore our entire collection of Miller tools and accessories.
Frequently Asked Questions
What makes the Miller Maxstar 161 STL TIG and Stick Welder versatile?
The Maxstar 161 STL combines two processes — TIG welding and stick welding—in one compact, portable machine. It delivers smooth TIG arcs for precision work and steady stick performance for heavier materials. With its built-in gas solenoid, digital interface, and reliable welding output, it’s designed for maximum versatility on various metals and job types.
Can the Maxstar 161 STL weld aluminum?
The Maxstar 161 STL is a DC-only TIG welder, which means it can easily handle mild steel, stainless steel, and other thin materials. However, it is not ideal for aluminum TIG welding, which typically requires AC current. For aluminum projects, Miller Syncrowave or Multimatic models are better suited.
What power requirements and accessories are needed to start welding?
Getting started is easy; all the accessories are on our website. You’ll need standard power cables, a TIG torch, a stick electrode holder, and a gas hose and valve setup.
The Maxstar 161 can also run on 120 V power with the proper adapter, offering flexibility in the shop or field.
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