Companies are choosing robotic automation to help bridge the gap. The technology has progressed since the first spot welding robot was introduced in 1962. Today robotic welding is primarily used for high-volume, repetitive processes.

“Traditional automated systems are good at performing the same task over and over,” he says. “The capital investment though, is just the first step. It can take months to build a cell and weeks to complete installation and get it up and running. Programming is time consuming and requires its own skills. If a part model changes, you are faced with additional programming and tooling.” A job shop may save money on labor but, short term, an automated welding system requires a considerable investment that takes time to recoup.”

Cobots have the potential to eliminate complex programming and introduce a greater degree of flexibility. A plug-and-play seven-jointed cobot can reach angles that are not reachable with a traditional 6-axis cobot. In addition to adjusting and adapting to different tasks, speed matters. In most cases, weld penetration into a base material increases when the travel speed of the weld decreases. Moving too slowly can result in excessive weld deposition. “A teach-by-demonstration cobot may soon have the capability to perform precision welds to a customer’s specifications,” Bogart says. “Without the need for programming, an individual with fewer skills could show the cobot where to weld. We see a lot of potential for cost-efficient cobots in this arena.”

Laser beam welding is growing fastest, followed by resistance welding. The development of sensors to communicate real-time information will be a crucial next step. We see the use of automated welding continuing to grow over the next decade as job shops look for ways to reduce part costs, and improve efficiency and accuracy.”