Optimize Automation and Robotics
Leading the list of solutions to address the struggle for skilled workers in the metalworking industry is the embrace of automation, digital connection, and robotics into processes. Industry suppliers continually introduce innovations and advancements in machinery, material handling solutions, software, digitalization, AI, and more, to support this transition.
By introducing automation in phases, such as in bottleneck-prone areas of production, and tasks such as deburring and grinding, and material handling and storage, metalworkers achieve gains they can measure and see. With these wins they can set realistic goals and scale up to the next round of automation and robotics and interconnected systems, among other tools.
Not only do these advances make metalworking jobs more accessible to inexperienced workers, but they also play a major role in eliminating inefficiencies, supporting precision manufacturing and meeting ever tighter tolerances — while improving factors such as flexibility and safety in manufacturing processes.
Multitasking Machine Center and Ez Loader Enable Single-setup Automation
At DISCOVER 2025 held in October, the Mazak Corp.’s (Florence, KY) INTEGREX i-250H ST Multi-Tasking Center showcased part-processing agility with the power of a full CNC turning center and the versatility of a full-function machining center. For DONE IN ONE® machining, the INTEGREX i-250H ST features a second turning spindle (S), along with a milling spindle and lower turret (T) with optional rotary tool capabilities. This configuration boosts productivity with minimal fixturing, part handling and less non-cut time.
The machine enclosure, tool magazine and optional auto jaw changer accommodate a comprehensive range of automation technologies, including gantry loaders, bar feeders and articulating robots. At DISCOVER, the INTEGREX i-250H ST was demonstrated with an Ez LOADER for simple, single-setup automation. The MAZATROL SmoothAi CNC enables the multitasking machine to carry out standard specialized operations such as crankshaft inclined drilling and gear skiving.
Easily Automate Material and Part Flow with Shear Brilliance
Prima Power North America’s (Arlington Heights, IL) Shear Brilliance, which is an ideal solution for manufacturing big square parts and panels, features servo-electric technology, and linear drives to achieve impressive performance values, which translate into new levels of productivity in versatile, flexible fabrication.
The vast majority of all sheet metal components fabricated are rectangular, so a highly economical method to produce them is to perform punching and then shear the components loose in the same automatic process with an integrated right angle shear. Parts with three or two straight edges are also ideal for fabrication with a right angle shear.
The Prima Power right angle shear features a programmable blade height and automatic stroke depth adjustment to optimize shearing. The blade speed is automatically selected for the maximum speed, which together with automatic shearing modes, optimizes operation speed.
Shear Brilliance can be easily connected to automation systems in order to automate the material and part flow and further increase the output.
When paired with Prima Power’s PSBB line (Punching + Shearing + Buffering + Bending), material flow is arranged in flexible ways. The PSBB line automatically processes blank sheets into ready-bent, high-quality components. The PSBB line transfers parts directly to automatic bending, to balance the different time requirements of bending and punching/shearing, to exit material from the system and to bring new material into it. The flexible and versatile buffering function ensures that optimum operation in terms of manufacturing cost and throughput time can always be selected, no matter the task at hand. This flexibility ensures the optimal operation of integrated machines.
A Simple Solution for Automated Material Transport
Automating material transport in manufacturing poses challenges for many companies, typically requiring digitization and networking a shop’s entire manufacturing process, which can be costly. With the Material Flow Starter Kit, TRUMPF (Farmington, CT) has developed a solution that is easy to use and requires less installation effort. With this solution, mobile robots transport the material through the production process. The vehicles can be controlled via a web application that works on any mobile device in the user’s network.
The Material Flow Starter Kit allows the mobile robots to access up to nine stations. These include machines in the sheet metal production area, as well as manual workstations or the shipping area. Up to eight transfer points can be specified for the goods to be transported to each station. As soon as a production employee wants to transport the parts they have processed, they request the mobile robot via the web app. This enables them to transfer the workpieces to the vehicle on a pallet trolley without needing to leave their workstation. The mobile robot can transport loads of up to one ton, making it suitable for the majority of components in sheet metal production. Changes to the route plan, for example, if a machine changes location, can be carried out by the customer themselves using an included software.
When commissioning the system, a service technician guides the mobile robot through the factory with a tablet. During this process, the vehicle scans the environment with its built-in sensors and creates a virtual map of the factory. The technician then creates the route with its associated process steps at each individual station such as bending, punching and laser cutting in the software tool. In the final step, the web application seamlessly sends the transport order to the vehicle. This allows the mobile robot to navigate autonomously and safely through the production process.
The Material Flow Starter Kit is suitable for companies that want to digitalize their production in stages. “Once companies have gained initial experience with the Material Flow Starter Kit, we recommend introducing TRUMPF’s Oseon software,” said Walter Kampitsch, automation group manager for the TRUMPF Smart Factory in Hoffman Estates, Ill. This allows them to synchronize the material flow with the production plan. This way, the material always automatically goes to where it is needed — without disruptions and paperwork.”
TRUMPF developed the Material Flow Starter Kit in cooperation with its partner SAFELOG. Thanks to the partnership, TRUMPF customers can also use SAFELOG’s other robot solutions.
High-speed, Low-cost Laser Cutting Machine with Modular Automation System
The cost-effective ORSUS 3015 AJe 6kW fiber laser cutting solution incorporates many of AMADA AMERICA, INC.’s (Buena Park, CA) industry-leading features. The ORSUS 3015 AJe machine offers a working range up to 3,070 mm-x-1,550 mm, and oscillator outputs of 3 kW, 6 kW and 8 kW. The machines realize high-speed, high-quality machining due to the adoption of a carriage with a low center of gravity to support high acceleration and deceleration.
The machines offer fabricators exceptional cost-to-performance value with i-Process Monitoring, automatic nozzle change/centering, laser head collision recovery, and single pallet automation. The machine processes thin-to-thick materials without manual setup. The EZ Fast Cut provides high-speed and low-cost processing especially on medium-thick plate. The i-CAS allows operators to set up and cut on remnant materials safely and easily.
Among the advantages of AMS 3015 CL is that the automated system supports multiple lasers and enables quick upgrades in order to expand with future requirements thanks to the modularity of the system. What’s more, this automated system reduces lead times, as well as labor and operating costs.
Another automated system from AMADA, the ORSUS 3015 AJe + CL + SCP, made its debut at FABTECH 2025 in Chicago.
New Robotic Bending Cell
BLM GROUP USA (Novi, MI) now offers the ProBend HBS II robotic bending cell, a completely customizable bending solution for any part mix metal fabricators need to form, regardless of size.
“The ProBend HBS II gives our customers the flexibility they need in their forming operations, even those with high product mixes, which is unique in the marketplace,” said Israel Arenas, product specialist for press brakes at BLM GROUP. “Through our extensive research and development, we are confident that this new machine will help our customers take their production to the next level.”
BLM GROUP engineered the ProBend HBS II to provide high-speed bending guided by an integrated Sheet Following System. This system offers real-time synchronization between the robot and the press brake and adjusts movements dynamically to ensure precise bends and minimize scrap or defects. Designed with productivity and precision in mind, this new bending cell also provides a fully automated workflow. From sheet loading and bending to palletizing, the ProBend HBS II manages the entire process with minimal operator intervention, helping reduce labor costs and the opportunity for errors.
This compact cell includes flexible and adaptive gripping by way of multiple robot grippers that offer quick-change capabilities. This allows for seamless handling of various workpiece sizes and geometries. Equipped with an automatic auxiliary loader, centering table and thickness control system, the ProBend HBS II accurately positions the sheet and prevents double-sheet processing that can lead to costly defects.
The ProBend HBS II is simple to use, allowing operators of any skill level to run the machine. It includes a 17” touchscreen supervisor PC that is intuitive to use, along with a Teleservice Module that enables remote diagnostics and support.
Intuitive simulation tools and integrated software make programming the ProBend HBS II a straightforward process. To improve efficiency and provide seamless connectivity, the ProBend HBS II features SimulEasy 1.0 offline programming software that can program the robot and press brake simultaneously. This software provides capabilities such as press brake set up, robot path generation, and simulation and error detection. Operators can also create optimal robotic movements for part handling, define tooling, verify bends and adjust bending styles and part orientations to ensure safe movements with one software.
Digital Manufacturing Workflow Refines Factory Floor Optimization
Visual Components North America Inc. (Carmel, IN), a provider of advanced 3D simulation expertise and offline robot programming (OLP) and manufacturing process simulation software, enables metal fabricators to configure layouts for machines, manual labor processes, robotics, AGVs, and more, to optimize current facility floor layouts or plan for floor optimization at new facilities.
Investments in machinery present risks and uncertainties when it comes to trial and error in real-world operations, which can waste time and money. Simulation tools reduce this risk by allowing companies of all sizes to virtually test different system iterations, validate outcomes with data, and select the best option. This acts as a safeguard — almost like an insurance policy — before committing to major investments, noted Todd Marshall, Sales Manager-Americas for Visual Components.
“Automation isn’t something that just happens with a snap of a finger,” he added. The software from Visual Components offers a virtual sandbox that allows metalworkers to develop the best possible layouts and solutions for their shops.
“We’re really focusing on dialing in those processes and then generating statistical data to validate your proof of concept,” Marshall said. “We have statistical data that can be anything from cycle times, throughputs, buffer capacities, system outputs, defects — anything and everything that you can think of.”
For example, through PLC connectivity and simulation of your shop’s machines, digital twins are created so the simulation matches what happens live in the production process, as well as virtual robotic conditions. The company is robot agnostic. With offline programming, Visual Components can take a 3D CAD file of a part that is being worked on such as welds, surface prep functions, and more, and generate “100 % of the robotic programming with individual components, and then we post processes into the native robotic manufacturers programming syntax,” Marshall noted.
Another area of value regarding simulation software for robotics focuses on quality assurance considerations. By taking a CAD file and using virtual simulation, the results will be as accurate as the CAD file when it comes to programming, Marshall noted. He used the examples of circular cuts, or grinding bolt holes, where users will comment they haven’t experienced as good of a cut or robotic programming for this application. “It is because we are tying the virtual concept to the real-life product with exact specifications to create a more streamlined robotic programming and manufacturing process,” Marshall noted. “It’s all about getting as fast as you can from concept to reality.”
Compact Bending Automation System for any Production Environment
Bystronic Inc.’s (Hoffman Estates, IL) ByCell Bend Star M is based on the recently launched ByBend Star 120 press brake and fills the gap between the small mobile bending robot and the large bending cell. The ByCell Bend Star M is just as ideal for processing job lists as it is for changing orders — from small batch sizes to large series. In combination with the ByBend Star 120, the agile robot completes bending jobs fully automatically and without errors.
The Bend Star M offers the benefits of a bending cell but with the advantage of a compact, modular layout. With a footprint of just 21.32’-x-20.34’, it maximizes space without compromising on performance.
At the heart of the automation system is the latest generation KUKA IONTEC robot. The machine is also equipped with RF-AC tooling — which enables automatic tool changing by the robot and seamlessly combines efficiency and flexibility. This automatic tool and gripper change has never been easier thanks to intelligent RFID technology.
The vision system eliminates the need for referencing, saving valuable time on each part produced — around 10-to-15 seconds per part, which has a significant impact throughout a shift. With many modular options, the cell can be configured according to individual requirements — from small options such as brushes or magnets for sheet separation to automatic tool changers.
Automated Cutting Machine is Bigger, Sturdier, Safer and Easier to Service
ESAB (North Bethesda, Md.) has unveiled its Suprarex PRO, an enhanced version of its heavy-duty, large gantry automated cutting and beveling machine for wind tower, ship, oil and gas, tank and pressure vessel, rail car and other large plate applications. The enhancements include a larger and sturdier gantry beam and modernized side carriages with a massive design that delivers exceptional stability at travel speeds up to 40 m/minute (1,575”/minute). Track width options are available up to 10.5 m (34.45’) to accommodate cutting areas up to 9.5 m (31.17’).
The Suprarex PRO gantry can be equipped with up to four standard plasma torches, two DMX bevel systems, 12 oxyfuel torches, ESAB’s IR-VBA infinite rotation oxyfuel bevel head, ESAB’s SmartJet Green hydrogen cutting technology and a Drill System 307 for drilling, threading and counter boring and marking systems including pin stamp, inkjet, plasma, punch or scribe marking.
The DMX Beveller works in conjunction with ESAB’s SquareCut Technology, which can further improve the productivity of automated plasma cutting operations. SquareCut Technology tilts the torch to compensate for the edge angle inherent in high-precision plasma cutting to provide three distinct benefits: a High-Speed Mode cuts up to two times faster without increasing bevel angle; a Quality Mode creates a cut surface with a 0°- to-1° bevel; and improved Enhanced Hole Technology cuts smaller holes with better cylindricity.
Automation Powerhouse Duo Debuted at FABTECH
The FG3015 Sorting Loader from Muratec USA (Charlotte, NC), a Murata Machinery Brand, automates sheet loading, parts sorting, and skeleton unloading with advanced servo control and programmable stacking. Designed for high efficiency and reliability, it supports sheets up to 5′-x-10′ and 2-ton stacks.
Despite being the largest in the FG Series, it maintains a compact footprint with same-side material flow
and optional manual load/unload. It is ideal for high-mix, high-volume operations seeking smart, space-efficient automation.
Muratec demonstrated its latest advancements with a dynamic pairing at FABTECH 2025: the MF30510HL combination punch press/fiber laser and the FG3015. “Presenting the MF30510HL alongside the FG3015 marks a milestone in our ongoing mission to streamline and elevate sheet metal manufacturing,” said Jeff Kalmbach, general manager of Muratec USA’s Machine Tools Division. “Together, these machines offer unmatched multifunctionality, empowering job shops to run faster, smarter, and with greater confidence in today’s high-mix, high-demand environment.”
“The FG3015 represents our latest step toward truly intelligent automation,” said Matt Ward, fabrication
business unit manager at Muratec USA. “Today, automation isn’t a competitive edge — it’s a requirement.” Manufacturers of all sizes can harness integrated solutions to reduce labor
dependency, increase throughput, and stay resilient in a changing market, Ward noted.
www.muratec-usa.com/products/658
Flexible Robotic Wet Machining
The FANUC America (Rochester Hills, MI) M-810/270F-27B industrial robot, which supports flexible robotic wet machining, was on display at FABTECH 2025. The M-810 offers a 1.3 times larger operating space and supports 3.4 times higher machining load compared to the previous model M-800. Featuring a high-rigidity arm, high-precision calibration for accurate path control, and unique technology to maintain tool path even under machining reaction forces during operation, the robot is applicable to high machining loads.
It is also capable of milling, drilling, and tapping on steel workpieces that require higher performance than the M-800. It is compatible not only with dry machining, where chips are dispersed, but also with wet machining using cutting fluids.
At FABTECH, the robot milled and drilled aluminum stock using a variety of tools and accommodated various mounting positions. Built to withstand harsh elements like water and debris, and known for its rigidity and accuracy, the robot offers a larger work envelope compared to similarly priced CNC machines. Additionally, its adaptability makes it suitable for repurposing across various applications.
New Standardized Robotic Welding Solution
KUKA Robotics’ (Shelby Township, MI) arc_cellerate Index cell is a flexible, high-performance automation system with a compact design to meet diverse application needs. The standardized cell enables manufacturers to optimize welding applications, simplify entry into robotic welding, and boost overall productivity at a lower cost. The solution is designed to offer an economical and efficient option for high-mix, low-volume applications.
Available in both Index and SBS (side-by-side) configurations, these fully equipped cells come with KUKA’s long reach KR CYBERTECH nano hollow wrist Edition series robot and are ready to perform a range of welding tasks, delivering exceptional flexibility for diverse manufacturing needs. They are available in both single and multi-station setups. The pre-engineered cells are easily installed, and provide repeatable, reliable automation that enhances productivity, ensures consistent quality and delivers necessary flexibility for a variety of welding applications.
Seventh-axis Linear Track Solves Work Envelope Challenges for Cobots
At this year’s FABTECH, Güdel Inc. (Ann Arbor, MI) unveiled the CoboMover™, a 7th-axis linear track purpose-built for collaborative and lightweight robots. “The CoboMover is designed to help integrators and end users expand the range of cobot and lightweight robot applications, with the same reliability, repeatability, and ease of use which Güdel’s global customers have become accustomed,” said Brenda Courim, head of sales for Güdel Inc. “The CoboMover is more than just another linear axis — it’s a game changer.”
It extends the working range of robots up to 5 meters (16.4’), allowing them to operate multiple workstations and perform a variety of tasks without manual repositioning. The new track is compatible with more than 60 cobots and small traditional robots and offers mounting positions at 0° and 180°. The maximum payload, including robot weight, is 78 kg (172 lbs.) with a drive system utilizing a toothed belt and Güdel’s HPG045 angular gearbox. Available stroke lengths include 1,000, 2,000, 3,000, 4,000, and 5,000 mm. The CoboMover has a maximum speed of 2 m/s and a maximum acceleration of 2 m/s², providing a repeatability of ± 0.05 mm.
Inexpensive App for Robotic Monitoring of Automation Cells
Machinery Automation can now assist their customer faster by remotely monitoring, diagnosing
and troubleshooting from their headquarters in Pennsylvania.
Olis Robotics (Seattle, WA), has created an inexpensive app for Android devices that allows fabricators to use their mobile devices as the gateway to remotely manage automation cells. By connecting their mobile device to a PLC through the app, fabricators can remotely control a robot and view live video of a remote system with PLC/telemetry data overlaid, allowing them to diagnose automation issues instantly from anywhere in the world. In addition to receiving synchronized telemetry and video in parallel, engineers can create alerts regarding irregular activity before it escalates into a costly manufacturing issue. The Olis Robotics app, which costs $499, also supports screen-sharing functionality, enabling troubleshooting teams to collaborate in real time, pointed out Fredrik Ryden, CEO of Olis Robotics.
Mid Atlantic Machinery Automation (Palmyra, PA), part of the Mid Atlantic Machinery Group, is an early adopter of the monitoring, diagnostic and error recovery app from Olis Robotics. The companies demonstrated the app in real time, which was monitoring a press brake automation cell at FABTECH 2025.
“We focus primarily on automation for press break tending and sheet metal applications,” said Josh Mayse, co-founder and vice president of Mid Atlantic Machinery Automation. “We have over 50 deployed systems in North America and we cover all major brands of press brakes. We have patented end-of-arm tooling solutions and provide a turnkey solution.”
Mayse said his role as an integrator is to prepare manufacturers to be more effective and productive by deploying automation, for example, where they can run multiple press brakes and robots, operated by one team member. The automation cells then become a labor force multiplier. Mayse said that the ease of use and adaptability of automation cells is increasing. “The second half of this year — things are just blowing up with work,” he added. “The time has come for automation. We work together with Olis, who has developed a best in the world technology, as far as I’m concerned, which allows us to provide remote monitoring and support.”
Mayse pointed out that formerly such systems required the purchase of EDGE computing systems, which can be more complex and more expensive. With the Olis Robotics app, “all you need is an Android tablet and a tripod and the software,” he said. “I deploy this with every system we sell now because it allows us to give the customer world class support. If their robot goes down, we’re plugged in.” Mayse’s team is able to view inside an automation cell from anywhere in the world, viewing the same screens their customers see. “We can very easily get to the problem instead of asking 15 questions to figure out what the operator’s dealing with,” Mayse added. What’s more, the team might not even have to ask half those questions because they can very quickly scan what is occurring within the cell.
Ryden added that the Olis Robotics app allows companies to operate as if they had an army of customer service technicians that can be anywhere, anytime. “With a relatively small crew they can still get that reach and that footprint — all through an inexpensive Android app,” he said.
The next level of the product would be to provide machine metrics of some type, allowing automation cell users to sort through data to explore why a robot is or isn’t running, Ryden noted. For example, running out of parts isn’t a problem of automation but rather making sure the parts are in place. And, oil dripping on parts introduces bad incoming material into an automation cell. “It is not about blaming people,” Ryden added, “it is about solving the problem fast.”
www.midatlanticmachineryautomation.com
New Configurable Robotic Bending Systems
LVD Co. nv (Gullegem, Belgium) now offers the Robotic Bending Systems (RBS) in three configurable platforms. These systems form the foundation for fully customized cells, with choice of press brake capacity and functionality, input and output stations and style of robot grippers based on a fabricator’s application needs and production demands. The RBS units offer flexibility, making bending automation more accessible for a wider audience, allowing for a faster ROI for each system.
The three core platforms are:
- RBS 4 is designed for parts up to 600 mm-x-400 mm in size and weighing up to 4 kg. The maximum profile length is 600 mm. The system is compatible with press brakes featuring 1,500 mm or 2,000 mm working length, and 40 tons or 50 tons of pressing force.
- RBS 40 handles parts up to 1,600 mm-x-1,200 mm, with a maximum weight of 40 kg. The maximum profile length is 2,000 mm. The system is compatible with press brakes featuring 2,500 mm or 3,000 mm working length, and 80 tons, 135 tons, or 220 tons of pressing force.
- RBS 80 is designed for larger parts up to 3,050 mm-x-1,250 mm, weighing up to 80 kg. The maximum profile length is 3,000 mm. This system works with press brakes offering a working length of 3,000, 4,000, or 4,200 mm, and a pressing force of 135 tons or 220 tons.
The RBS units also include the Touch-B control; the CADMAN-SIM software which automatically programs both press brake and robot; the Easy-Form Laser adaptive bending system (optional); and a manual operation mode.
Long-reach Cobot Tackles the Most Demanding Automation Challenges
The new UR8 Long from Universal Robots (Novi, MI), part of Teradyne Robotics, offers the same 1,750 mm (68.9”) reach as the popular UR20 and a significantly slimmer profile. It combines reach, stability and precision in a rugged, compact, lightweight form, featuring an 8kg (17.6 lbs.) payload. This makes it ideal for space-constrained setups and industrial tasks, from complex weldments to precision dunnage picking and flexible multi-point inspections.
“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,” said Will Healy, global industry manager for fabricated metals at Teradyne Robotics.
“Whether it’s lifting, moving, or handling tasks that are repetitive or hard on the body, this robot makes the job easier,” said Jean Pierre Hathout, president of Universal Robots. “Its longer reach means it can cover more space, and its advanced features open new ways to automate work that used to be done by hand.” UR8 Long runs with both PolyScope 5 and PolyScope X, UR’s industry-leading software platform, and can be extended with MotionPlus control technology.
New Automation-ready Workholding Products
HWR Workholding USA (Fortville, IN) has launched a pair of new products designed to further support manufacturers seeking efficient and reliable automation systems. The INOFlex VF-A hydraulic 4-jaw chuck offers exceptional performance in turning applications, while the SOLIDPoint Pneumatic Coupler simplifies integration of SOLIDLine modular zero-point workholding with an existing pneumatic system.
Developed with automation in mind, the INOFlex VF-A 4-jaw chuck features hydraulic actuation that allows workpieces to be changed more quickly and enables a fully automated process. Like all INOFlex chucks, the VF-A incorporates patented compensating technology that lets each pair of jaws act more independently of the other. This provides automatic centering of workpieces of all sizes, allowing shops to quickly shift between circular, rectangular and asymmetrical parts.
The SOLIDPoint Pneumatic Coupler offers a simple, direct way to integrate the SOLIDLine family of modular zero-point workholding with a shop’s existing pneumatic system. While many manufacturers are already using the platform’s vises, risers and pyramids with palletized processing, the Pneumatic Coupler now provides the means to load and unload workpieces from vises via robotic automation.
