Advances in Welding Technology
Owning to cutting-edge innovations, welding industry operators continue to produce high caliber components thanks to user-friendly equipment that integrates real-time monitoring, which minimizes errors, and increases productivity, all the while reducing labor costs.
Increase the Stability of Laser Welding
Currently, the only way to guide the laser beam during the welding process is via the welding robot — but TRUMPF’s (Farmington, CT) new BrightLine Scan technology will also allow users to guide the laser beam using the laser scanner.
The combination of robot and scanner makes it possible to supplement the forward motion of the robot with a further, freely programmable movement of the laser in any desired direction. This “oscillating motion” is facilitated through specially developed lightweight mirrors. By enabling scan frequencies in the kilohertz range, this technique increasing the thickness of sheets that can be processed in heat conduction welding from 0.12”-to-0.24”. Users can tailor the parts’ bonding surfaces — which are melted directly by the laser beam — to suit each application. The fact that the beam can be guided using the scanner makes it easier to achieve tighter tolerances.
The scan technology is a reliable solution for welding sheets up to 0.24” thick, ideal for producing agricultural and construction machinery. The quality of the seams also makes it ideal for manufacturing furniture products and EV battery trays, as well as for producing electrical cabinets.
Robots Solve Difficult Applications
KUKA Robotics (Shelby Township, MI) featured flexible welding robots and next-generation automation technology at FABTECH 2025. In a demonstration, the KR IONTEC ultra 6-axis robot and KR CYBERTECH industrial robot were paired with an Electrically Actuated E Series magnetic gripping solution from Magswitch Technologies, which showcased compact, configurable automation for challenging applications. The KR IONTEC was combined with Magswitch Technologies’ ELAY50X5 switchable permanent magnet to assemble a 12-foot-long steel truss for the construction industry. With the support of KUKA. RoboTeam software, the robots coordinated material handling of the truss, while two KR CYBERTECH robots simulated robotic arc welding of its components.
The KR CYBERTECH nano ARC Edition delivers simple, cost-effective welding. The robot is available in two reaches from 1,440 mm to 2,010 mm and features a hollow wrist with bearings on either side of the robot with a diameter of 46 mm and a repeatability of 0.04 mm.
Slim, Long Robot Arm Delivers Precision
With the same 1,750 mm (68.9”) reach as the popular UR20 and a significantly slimmer profile, the UR8 Long from Universal Robots USA, Inc. (Novi, MI) combines reach, stability and precision in a rugged, compact, lightweight form, featuring an 8 kg (17.6 lbs.) payload. This makes it ideal for space-constrained setups and industrial tasks, including complex weldments.
“UR8 Long delivers an easier teaching experience than traditional welding robots, better weld quality than manual welding, and less overall rework, saving time and money,” said Will Healy III, global industry manager for fabricated metals at Teradyne Robotics. “Following feedback from fabricators around the world, the UR8 Long was designed with the collaborative welding process in mind, boosting productivity and helping leaders to attract new talent who are often more motivated to operate a robot than perform repetitive manual welding.”
Rethink Productivity and Training
ESAB’s (North Bethesda, MD) Dueler EHL 1500 is a compact, air-cooled, 1,500-watt handheld laser welding system designed for welding at speeds up to 4X faster than TIG and 2X faster than MIG. The Dueler enables operators to make high-quality, consistent weld seams and joints with minimal training. Its intuitive 7” touch screen interface offers two modes: manual (for advanced users) and synergic for simplified operation using factory-programmed settings for common metals.
Fabricators should consider adding a laser welder when they need to reduce heat input (minimize warping, burn-through and the Heat-Affected Zone), want to reduce post-weld cleanup or grinding to improve bead appearance, need to increase productivity without adding highly skilled staff or need to increase weld quality (more reliable fusion, reduced porosity).
