Welding Automation Delivers Benefits to Manufacturers Large and Small

The world is grappling with a growing shortage of skilled welders, a crisis felt across industries from automotive to aerospace. Welding is an essential trade, yet it comes with challenges that deter younger generations: exposure to fumes, physical strain, and repetitive tasks under intense concentration. As a result, the average age of welders is climbing, with many nearing retirement, leaving a gaping hole in the workforce. By some estimates, the United States alone needs an additional 85,000 welders immediately, with the global demand expected to rise by over a million in the next 25 years. For businesses dependent on welding, this shortage spells delays, bottlenecks, and strained relationships with customers.

The impact of the welder shortage is evident on shop floors worldwide. Companies are resorting to desperate measures, such as extended overtime hours, to keep production moving. While overtime may offer a temporary solution, studies repeatedly show diminishing returns. Research dating back to post-World War II defense production revealed that productivity begins to decline after 50-hour work weeks and plummets significantly beyond 60 hours. Modern studies have reinforced this, citing not only reduced productivity but also increased safety risks, poor mental health, and higher employee turnover.

These inefficiencies exacerbate the problem for fabricators who find themselves unable to meet current customer demands, let alone grow their business by taking on new projects. Smaller shops are particularly vulnerable, with limited manpower and resources to offset production delays. The need for a scalable, sustainable solution has never been more urgent.

Enter welding automation, a technology that has been around since the late 1970s but has recently undergone a revolutionary transformation. Traditional robotic welding systems, while effective, come with several limitations: they require significant floor space, specialized programming expertise, and long lead times for implementation. Additionally, their lack of flexibility makes them an expensive proposition, accessible only to large-scale manufacturers with deep pockets.

This is where collaborative robots (cobots) step in, redefining what’s possible in welding automation. Unlike their traditional counterparts, cobots are designed to work alongside humans, bringing unparalleled flexibility, cost-effectiveness, and ease of use to fabrication shops of all sizes.

Cobots have emerged as a practical solution to the challenges of welding automation, making advanced technology accessible even to small and medium-sized shops. Here’s why cobots are transforming the welding industry:

• Minimal Space Requirements

  Cobots operate safely without the need for bulky barriers or dedicated zones. With a proper risk assessment and operator personal protective equipment (PPE), cobots can integrate seamlessly into existing production lines, leveraging the shop’s current tooling and fixtures.

• Ease of Programming
  

  Unlike traditional robots, which require specialized engineers, cobots can be programmed and operated by skilled welders. This democratizes automation, enabling experienced welders to quickly adapt to new parts and processes. Programming a new part can take minutes, not hours, ensuring maximum uptime.

• Faster Deployment Traditional robots often take months to design, build, and deploy. Cobots, on the other hand, can go from purchase order to production in as little as three to four weeks. For shops facing immediate labor challenges, this rapid implementation is a game-changer.

• Affordability Cobot welding systems cost significantly less than traditional automation—typically one-third to half as much. With lower upfront costs and faster ROI, they make automation an achievable goal for manufacturers of all sizes.

• Unmatched Flexibility Cobots are easy to move and reprogram, allowing manufacturers to adapt quickly to changing production needs. This versatility ensures that cobots remain valuable assets, even as product lines evolve.

One of the most compelling advantages of cobot welding is the ability to amplify the output of skilled welders. A common setup involves one experienced welder operating a cobot welding system. While the cobot handles arc-on tasks, the welder can focus on fixturing components and ensuring quality control. This dynamic not only maximizes arc-on time but also removes the welder from direct exposure to fumes and arc flash, creating a safer work environment.

In shops with higher automation maturity, one welder can manage two or even three cobot systems, further enhancing productivity. For larger weldments, welders and cobots can collaborate on the same part, provided proper safety measures are in place. By automating repetitive tasks, cobots free up skilled welders to tackle complex, high-value projects that require their expertise.

Cobots don’t just boost output they improve quality. Weld consistency is often a challenge for human welders, especially during long shifts or when dealing with repetitive tasks. Cobots, however, maintain precise control over weld parameters, torch angles, and positioning, ensuring consistent results. For parts with poor fit-up, advanced cobot systems equipped with vision, laser, or through-the-arc sensing can compensate, reducing scrap and rework.

Smaller, high-volume parts are particularly well-suited to cobot welding. These parts can be loaded and unloaded by operators, leaving skilled welders free to focus on more intricate tasks. The result is not only higher productivity but also reduced strain on human resources.

Fabricators around the globe are reaping the benefits of cobot welding. Swedish fabricator Vattholma Mekano reported a 30% increase in MIG welding productivity after implementing a cobot welding solution. Similarly, Raymath, a sheet metal fabricator in Ohio, achieved faster cycle times and improved weld quality with cobot systems for TIG and MIG welding. These success stories highlight the transformative potential of cobots, even in highly specialized industries.

Beyond the tangible benefits of productivity and quality, cobots are driving a cultural shift in manufacturing. By automating the “dull, dirty, and dangerous” aspects of welding, cobots improve job satisfaction, reduce safety risks, and attract younger talent to the trade. Employees who were initially wary of automation often become its biggest advocates, suggesting new ways to leverage cobots for improved efficiency.

As MT Solar’s CEO, Travis Jordan, aptly put it, “It’s hard to find good, skilled people that are willing to come up here and work.” Cobots address this challenge by making welding jobs more appealing, both to current employees and prospective hires.

The welding industry is at a crossroads, with mounting labor shortages threatening to stall progress in critical sectors. While there’s no quick fix to the global welder shortage, cobot welding offers a sustainable path forward. By embracing automation, manufacturers can not only survive but thrive in a rapidly changing landscape.

For those ready to explore the possibilities of cobot welding, the time is now. Join the global conversation at the upcoming virtual event on October 26, where industry leaders will share insights and strategies for leveraging automation to overcome the welder shortage.

Automation isn’t just a solution—it’s the future of welding. With cobots leading the charge, that future is closer than we think.