Robotic welding integration
We deliver advanced solutions in the field of robotic welding integration, dedicated to machine manufacturers, system integrators and production plants. Combining expertise in design, programming and the full implementation of robotic workstations, we ensure the highest efficiency and safety of production processes.
What does robot programming consist of?
What does the robotic welding integration service include?
As part of robotic welding integration service we comprehensively integrate industrial robots with dedicated tooling as well as control and safety systems. Our team carries out the entire process – from a thorough technological analysis and the precise selection of equipment, through advanced programming of welding robots for optimal movement paths, all the way to implementing vision systems and wire feeding systems. We complete the entire implementation with a virtual and physical commissioning of the workstation, as well as professional operator training, which guarantees a smooth and safe transition to the new production standard.
Do you want to introduce robotic welding in your plant?
We provide solutions that genuinely increase line efficiency.
Why entrust us with the robotic welding integration?
Our experience in implementing complex industrial automation projects, including demanding deployments for automotive market leaders, allows us to offer solutions that go beyond standard approaches. Welding automation it is not only programming robots, but above all the optimization of the entire technological chain, therefore our approach is based on partnership and a deep understanding of your business goals – so that the investment translates into real profit.
No complications caused by staff changes.
The industry standard is a high turnover of specialists, which often leads to unforeseen delays and complications in the implementation process. At Amister, we emphasize the stability of our team.
Transparency of the process and a partnership approach
We have observed that clients often have to contact multiple people to determine the progress of a project, which makes it difficult to manage next steps. We also know that unclear scopes of work and expectations can lead to conflicts.
Guarantee of quality and timeliness
Many projects on the market are carried out by people without the appropriate experience, which results in lower quality of execution. At Amister we take care of the development and quality of our team.
Join the ranks of satisfied customers
See how we increase welding efficiency for global leaders and find out what we can improve on your production line.
Experience confirmed by leading projects
We implement solutions for the largest players in the industry. See how we program welding robots, squeezing maximum efficiency out of every second of the production cycle.
Mercedes Benz engine assembly line Jawor
V8 engine cylinder head installation – Jaguar Land Rover (NC11)
Industry leaders trusted us.
Star Assembly LLC
Sebeș, Romania
Audi
Gyor, Hungary
BMW
Steyr, Austria
Stellantis
Mirafiori, Italy
BMW
Dingolfing, Germany
Daimler
Brühl, Germany
NIDEC
Niepołomice, Poland
Skoda
Mlada Boleslav, Czech Republic
Liebherr
Bischofshofen, Austria
Festo
Budapest, Hungary
Daimler
Untertürkheim, Germany
Dana
Amal, Sweden
Scania
Södertälje, Sweden
Volkswagen
Polkowice, Poland
Volkswagen
Salzgitter, Germany
Daimler
Redford, USA
Daimler
Kassel, Germany
Getrag
Cologne, Germany
Getrag
Bordeaux, France
Daimler
Jawor, Poland
Bosch
Charleston, USA
Great
Tychy, Poland
ZF
Toluca, Mexico
JLR
Wolverhampton, Great Britain
What production challenges does robotic welding solve?
The true value of robotic automation reveals itself in the areas that generate the greatest financial losses in the traditional, manual process. Modern robotic workstations effectively eliminate the most common technological, raw material-related and operational problems that production plants face.
Dimensional non-repeatability and thermal deformations of parts
Parts after cutting or bending are rarely perfectly even, and welding heat further deforms the material. Robotic systems equipped with touch-based geometry detection Touch Sensing and real-time through-arc seam tracking TAST – Through-Arc Seam Tracking automatically correct the torch trajectory. This enables stable process operation even with variable gap geometry.
Waste of welding material and a high amount of waste
In a manual process it is easy to make mistakes that result in irreversible damage to expensive components and the creation of scrap. Moreover, welders often deliberately “thicken” the welds, which generates uncontrolled consumption of wire and shielding gases. Robotic automation introduces precise dosing of filler material exactly according to the design assumptions. The robot uses only as much material as is necessary, which drastically reduces production waste and raw material costs.
Material burn-throughs and time-consuming metalworking of thin sheet metal
Manual joining of thin-walled components carries a huge risk of defects. Robotic automation enables the implementation of advanced low-temperature processes, such as CMT (Cold Metal Transfer). Precise digital arc control allows stable welding of thin parts and braze-welding of zinc with minimal heat input. This completely eliminates spatter and the need for secondary manual grinding of welds.
Costly machine downtime when implementing a new product range
In the classical approach, programming a new product requires stopping the workstation on the shop floor for many hours. The use of offline programming software allows creating and testing trajectories in a virtual 3D environment. Thanks to the mathematical calibration of the tool center point (TCP – Tool Center Point), the finished code is transferred directly to the machine, and the physical workstation is locked only for the time of final adjustments and validation, which drastically minimizes production downtime.
Quality fluctuations of welds and hindered certification of products
The human factor means that each weld may have slightly different parameters, which disqualifies the product in industries subject to stringent standards (e.g. ISO 3834). A robot guarantees repeatable timing and dynamics of arc travel every time. Additionally, the integration of power sources with data recording systems enables continuous recording of parameters (current, voltage, linear energy), ensuring 100% compliance with WPS instructions.
High risk of accidents and toxic working conditions for operators
Manual welding involves continuous exposure to toxic welding fumes, UV radiation and the risk of burns. Integration of industrial robots completely keeps a person out of the zone of direct danger. The use of advanced safety systems – such as optoelectronic curtains, laser scanners and certified zone-control software (e.g. SafeOperation, SafeMove or DCS) – enables the creation of a welding cell fully compliant with ISO 10218.
Shortage of qualified welders and the risk of sudden production stoppage
The market is struggling with a critical shortage of certified specialists, and high employee turnover hinders the timely fulfillment of contracts. Robotic automation makes the plant’s stability independent of labor market fluctuations. A robotic workstation guarantees a steady, predictable production pace, and experienced personnel can be reassigned to safer tasks related to process supervision and quality control.
Robot Programming – Certification
Daimler Integra 6
KUKA SafeOperation
Fanuc DCS
ABB SafeMovePro
Technologies that we use in the robotic welding integration
Choosing the right software and tools is the key to creating an efficient and reliable robotic workstation. As an integrator, we prioritize maximum comprehensiveness of actions — we deliver End-to-End systems in which advanced control and real-time guidance of robot arms, continuous assurance of parameter repeatability, and automatic handling of auxiliary processes form a single, stable, and highly efficient system. We use proven solutions from global leaders in automation, guaranteeing the highest precision, operator safety, and optimization of the work cycle.
KUKA
Programming KUKA robots using the Kuka SimPro and Kuka WorkVisual environments to create offline simulations and optimize motion trajectories.
ABB
Integration and programming of ABB robots using ABB RobotStudio, which enables the creation of virtual models of production lines and the testing of control logic before deployment.
FANUC
Configuration and programming of FANUC robots using tools such as Fanuc RoboGuide, which allows simulation of operation and optimization of work cycles in a virtual environment.
Epson
Integration of Epson high-speed SCARA robots within welding lines for the rapid feeding, positioning, and preparation of components before the actual joining process.
Vision systems
Configuration of advanced vision systems supporting robots in the precise localization of parts, real-time tracking of the weld trajectory, and automatic verification of its quality.
Measurement systems
Implementation of measurement systems dedicated to the control of welding and spot-welding processes, allowing real-time monitoring of pressing force and torque in order to eliminate production defects.
Welding systems
Programming advanced Fronius welding systems along with the precise selection of parameters to achieve the highest quality welds in diverse applications.
Siemens S7-1500
Programming Siemens S7-1500 controllers in the TIA Portal environment to manage the entire welding process, including robot motion control and integration with other peripheral devices.
In which industries and processes is robotic welding used?
Robotic welding integration requires a deep understanding of material-specific characteristics, quality standards, and cycle time optimization. Our experience allows us to implement advanced robotic workstations both in high-volume production and in the processing of large-scale components. We automate the entire technological chain – from part preparation, through precise joining, to integrated quality control.
Industries:
Automotive and transport
Series production assembly of body components, exhaust systems and robotic welding of frames, chassis and structures for the trailer, semi-trailer and special vehicle industry.
building prefabrication
Automated welding of serial structural elements for building construction and infrastructure.
Heating industry and HVAC
Automated welding of heat exchangers, central heating boilers, water heaters and tanks.
Energy sector
Welding of transmission pipelines, support structures, pressure vessels and turbine components.
Agriculture
Repetitive welding of frames, working arms, and structural components operating under harsh service conditions.
Aviation
Precision welding and resistance welding of engine components, skin elements, tanks and frame structures.
Heavy industry
Robotic welding of large-size and thick-walled steel structures and machine components subjected to extreme loads.
Metal industry
Repetitive processing of steel components, series production of building structures, trusses or railings.
Processes:
Arc welding MIG/MAG, TIG
Full automation of gas‑shielded welding, ensuring high penetration, repeatability, and excellent weld appearance.
Welding and spot welding
Robotic resistance welding of sheet metal panels and bodywork elements, guaranteeing maximum joint strength.
Laser welding
Implementation of laser technology for ultrafast and precise joining of materials with minimal heat input and no deformations.
Specialized welding
Automation of projection, butt, or friction welding processes in high-production-rate cycles.
Plasma cutting and beveling
Integration of robots with plasma units for precise hole cutting and preparation of part edges directly before the welding process.
Application of auxiliary materials
Precise robotic application of sealants, adhesives, or protective coatings in processes integrated with the welding line.
Operation of machines and positioners
Synchronization of the robot’s movement with the operation of rotators, welding tables, and multi-axis positioners in order to maintain the optimal welding position.
Robotic quality control
The use of 3D profile scanners and vision systems for immediate verification of geometry and detection of weld defects directly after the completion of the process.
Choose a collaboration model tailored to your needs
Choose the collaboration model that best meets the needs of your project. We offer a flexible approach tailored to the scale and specifics of your undertaking.
Model 1: Support as a subcontractor
The subcontracting model is specialized engineering support dedicated to integrators and machine manufacturers. We provide complete robot control software and advanced PLC logic, precisely integrating the entire digital layer with the workstation being designed or already in place. It is the ideal choice for companies that have strong mechanical and design capabilities and are looking for proven experts for the safe implementation and optimization of robotic welding processes.
Model 2: General contracting
The general contracting model is a comprehensive “turnkey” solution — from the initial concept and design, through construction, to final commissioning and staff training. We assume responsibility for the project, precisely integrating robots, PLC control, vision systems and peripheral equipment into a ready-to-operate robotic welding station. It is the ideal choice for facilities that prioritize modern process automation — without wasting their own time on technical details.
Choose secure robotic welding integration
We will take over programming and testing, delivering a system ready to work.
FAQ – Most Frequently Asked Questions
What does the duration of a robotic welding integration project depend on?
Typical implementation time for a workstation, from the analysis stage to final handover, ranges from a few weeks to several months. This time depends on the scale of the undertaking, the degree of complexity of the part geometry, the number of integrated robots, and the level of advancement of peripheral systems (e.g. positioners, vision systems, or advanced safety systems). We establish the detailed, safe schedule on an individual basis.
What information do you need from the client to prepare an offer?
To prepare an offer we need the technical specifications of the products (technical drawings, 3D models of the parts), a description of the current process (manual or semi-automatic) and the layout of the production area. Information about preferred robot brands, welding power sources and guidelines regarding internal logistics and plant standards will also be helpful.
In which industries and countries have you carried out projects?
We have extensive experience carrying out complex projects for demanding industrial sectors, with particular emphasis on the stringent automotive market. We have carried out advanced implementations for global leaders including Audi, BMW, Daimler and Volkswagen, both in Poland and in foreign markets such as Germany, Sweden, Austria, Romania, France, the United Kingdom, Italy, the United States and Mexico.
What does project coordination and communication look like during the implementation of robotic welding?
We prioritize full transparency and a partnership approach. To eliminate communication chaos, we assign a dedicated Team Leader to your project. He is your primary point of contact, fully up to date on the progress of the work. The client receives regular reports, and the project’s key milestones (including virtual simulations) are jointly discussed and approved before moving on to the physical installation phase.
Do you provide on-site support during the commissioning of welding stations?
Yes, it is an integral part of our quality guarantee. Our team of engineers implementing the project is present at your plant during the physical technological start-up and performance tests. We take care of equipment calibration and parameter optimization on the live system, ensuring a smooth transition to the new production standard.
Do you integrate welding robots with higher-level systems (MES, SCADA, ERP)?
Yes. We understand that modern robotic welding must fit into the factory’s business architecture. We develop intelligent control algorithms based on the Siemens S7-1500 and the TIA Portal environment that ensure flawless communication between machines on the line and enable secure data exchange with higher-level management systems.
Are you already modernizing existing older robotic welding stations?
Yes. In addition to designing and implementing new systems from scratch, we carry out advanced modernizations (retrofitting) of existing welding lines. We optimize motion paths, reconfigure arc parameters, implement modern vision systems for weld tracking, and adapt old safety systems to the currently applicable ISO standards.
Do you provide training for operators of robotic workstations?
Yes. We conclude every implementation with professional on-the-job training for operators and maintenance personnel. We teach the crew proper operation of the HMI, basic diagnostics, safety procedures and rules for handling as-built documentation, which guarantees your team’s full independence after the project is completed.
What safety systems do you implement at robotic welding stations?
All welding cells designed by us meet the stringent criteria of ISO 10218. We design virtual safety zones, integrate laser scanners, optoelectronic curtains and hardware emergency stop circuits. We have documented certificates and experience in the implementation of advanced zone protection software such as KUKA SafeOperation, Fanuc DCS and ABB SafeMovePro.
What production problems does the robotic welding eliminate?
Robotic welding effectively solves the problem of a critical shortage of certified welders and downtime caused by staff turnover, providing a fully predictable work cycle in a multi-shift system. In the production process itself, automation eliminates quality fluctuations and weld defects resulting from the human factor, reduces waste of wire and shielding gases, and also removes the need for time-consuming secondary metalworking. Robotic stations also eliminate the risk of hours-long line stoppages during the introduction of a new product range and keep employees away from toxic fumes and radiation.
Contact us – we will respond within 24 hours!
Do you have questions regarding robotic welding integration? Fill out the contact form, and our team will contact you within 24 hours – by phone or email.
During a conversation or correspondence we will jointly define the scope of the work and services that interest you. Then we will carry out an internal analysis of your inquiry to prepare the best possible solution.
Within a maximum of 5 business days we will get back to you with information about the next steps.
Take a step toward modern automation – fill out the form now!
