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The welding industry is facing a growing challenge: a severe shortage of skilled welders. In the U.S., the American Welding Society (AWS) estimates that 320,500 new welding professionals will be needed by 2029, while more than 157,000 welders are approaching retirement. The situation is just as critical in Europe, where the European Welding Federation (EWF) reports a shortage of around 300,000 qualified welders.
At the same time, demand for high-quality welding continues to rise across industries like automotive, construction, and heavy machinery. Companies struggle to fill positions, leading to production delays, increased labor costs, and lost business opportunities.
This is where collaborative robots (cobots) come in. Unlike traditional industrial robots, cobots are designed to work alongside human welders, making automation more accessible to manufacturers of all sizes. With user-friendly programming, increased flexibility, and lower upfront costs, welding cobots is rapidly becoming a game-changer for companies looking to boost productivity and maintain high-quality welds.
The global welding robot market is experiencing rapid growth, projected to reach $9.15 billion in 2025 with an estimated annual growth rate of around 10% over the next decade. Within this market, the cobot segment is expanding rapidly, taking an increasingly larger share as manufacturers seek more flexible, cost-effective automation solutions. This trend highlights a major shift in the industry — businesses are increasingly turning to automation to address workforce shortages, improve efficiency, and stay competitive.
What is a cobot?
A collaborative robot (cobot) is a type of industrial robot designed to work safely alongside human operators. Unlike traditional robots, which are typically confined to safety cages, cobots are equipped with advanced sensors, force-limiting technology, and intuitive programming interfaces that allow them to interact directly with workers.
Cobots were developed to bridge the gap between full automation and manual labor, making automation more accessible for small and medium-sized businesses. They are commonly used for tasks like material handling, assembly, quality inspection, and — increasingly — welding.
Key Features of Cobots
- Safety-first design: Built-in sensors and force limitations allow cobots to stop or slow down when they detect human presence, reducing the need for safety barriers.
- Easy programming: Many cobots use intuitive, no-code or low-code interfaces, allowing operators to set up and adjust tasks without extensive robotics experience.
- Flexibility & adaptability: Cobots can be reprogrammed and redeployed for different tasks, making them ideal for small-batch production and high-mix environments.
- Compact footprint: Unlike large industrial robots, cobots are space-efficient and can be installed in existing production lines without major modifications.
In recent years, cobot technology has advanced significantly, making them a practical solution for automating welding processes. Their ability to work alongside skilled welders, improve consistency, and enhance productivity makes them an increasingly attractive option in the manufacturing sector.
What is cobot welding?
Cobot welding refers to the use of collaborative robots (cobots) in welding applications, allowing manufacturers to automate welding tasks while maintaining flexibility and ease of use. Unlike traditional robotic welding systems, which require complex programming and safety cages, cobot welding systems are designed to work alongside human operators, making automation more accessible for businesses of all sizes.
How Cobot Welding Works
A cobot welding system typically consists of:
- A collaborative robot arm – Moves the welding torch along the programmed path.
- A welding power source – Provides the necessary electrical current for the welding process.
- A welding torch – The tool that delivers the weld, connected to the power source.
- Software & user interface – Allows operators to program the cobot with simple, intuitive controls.
Operators can easily teach the cobot welding paths by manually guiding the robot arm or using a touchscreen interface, making it far simpler than traditional industrial robots that require advanced coding skills.
Benefits of Welding Cobots
- Ease of Use – No need for advanced robotics expertise; quick to set up and program.
- Enhanced Productivity – Cobots can work continuously without fatigue, increasing throughput.
- Improved Weld Quality – Consistent, precise movements reduce defects and rework.
- Flexible Deployment – Cobots can be moved between workstations and reprogrammed for different welding tasks.
- Increased Worker Safety – Cobots handle repetitive, high-heat welding tasks, reducing strain and exposure for human welders.
With the growing shortage of skilled welders and rising demand for high-quality welding, welding cobots are emerging as a powerful solution for manufacturers looking to improve efficiency while maintaining flexibility.
Components of a Collaborative Robot Welding System
A cobot welding system consists of several key components that work together to automate the welding process while maintaining flexibility and ease of use. Each component plays a crucial role in ensuring precision, efficiency, and safety.
1. Collaborative Robot (Cobot Arm)
The robotic arm is the core of the system, responsible for precisely moving the welding torch along the programmed path. Universal Robots (UR), the company that invented the cobot, is the most widely used cobot brand in the world, particularly for welding applications. UR cobots are known for their ease of use, flexibility, and safety, making them an ideal choice for automating welding processes.
2. Welding Power Source
The welding power source supplies the necessary electrical current for the welding process. The integration options for power sources vary depending on the software you choose. Some cobot welding solutions are limited to specific welding machines, while others offer more flexibility.
With SmoothTool, you can integrate almost any power source, giving manufacturers the freedom to use their existing equipment or select the best power source for their specific welding needs. This flexibility ensures that businesses can optimize their cobot welding setup without being locked into a single brand or system.
3. Welding Torch
The welding torch is attached to the cobot arm and is responsible for delivering the weld. The type of torch used depends on the specific welding process, such as MIG (Metal Inert Gas), TIG (Tungsten Inert Gas), or laser welding.
4. Programming Flange
The SmoothTool package includes a programming flange that simplifies the setup and operation of the welding cobot. This flange allows operators to manually guide the cobot to define the welding path, making programming faster, more intuitive, and accessible for welders without robotics experience.
5. Wire Feeder & Consumables
In MIG welding applications, a wire feeder supplies the electrode wire to the welding torch, ensuring a consistent feed rate. Other consumables, such as shielding gas, contact tips, and nozzles, also play a role in maintaining weld quality.
6. User Interface & Programming Software
One of the key advantages of cobot welding systems is their easy-to-use programming interface. With solutions like SmoothTool, operators can program the cobot using:
- Teach pendants – Handheld controllers with touchscreen interfaces.
- Hand-guiding – Manually guiding the robot arm to define weld paths.
- Pre-programmed templates – Built-in software functions for common welding tasks.
This intuitive approach reduces the learning curve and allows welders with minimal robotics experience to set up and operate the system quickly.
Collaborative Welding vs Manual Welding and Traditional Automation
So how does welding with a cobot compare to traditional automation and manual welding?
To achieve an good understanding of the strengths and weaknesses of different welding approaches, let’s delve into a quick comparative analysis. In this table, we explore the key aspects of cobot welding, traditional automation, and manual welding.
By examining factors such as mix, volume, robotics skill, investment, and human presence, we aim to provide insights into which method may be the most suitable for specific welding applications.
So, let’s take a closer look at how these approaches stack up against each other in the world of welding.
| Best Fit | Traditional Automation | Collaborative Welding | Manual Welding |
|---|---|---|---|
| Mix | Low | Moderate to High | High |
| Volume | High | Low to Moderate | Low |
| Robotics Skill | High | Low | None |
| Welder Present | No | Yes | Yes |
| Investment | High | Moderate | Low |
Industrial robotic welding offers high speed and productivity, making it an efficient choice for large-scale production. However, its inflexibility necessitates a dedicated welding cell. While it proves advantageous for handling substantial batch sizes, implementing robotic welding can be costly and demands a skilled robot operator for programming.
Cobot welding offers a balance between the speed and accuracy of industrial robotic welding and the flexibility and adaptability of manual welding, making it ideal for low-volume, high-mix production runs and applications that require human collaboration.
Manual welding is the least expensive but requires skilled welders and can be dangerous if safety precautions are not taken. It excels in scenarios with a high mix of welding tasks but becomes less efficient as batch sizes increase.
Industries Where Welding Cobots are Well-Established
Cobot welding is revolutionizing metal fabrication across multiple industries. From heavy machinery and transportation to infrastructure and metalworking, businesses are leveraging cobots to increase efficiency, maintain high-quality welds, and address labor shortages. Below are some of the key industries where cobot welding has gained strong adoption.
Equipment Manufacturers
Manufacturers of industrial and mobile equipment rely on cobot welding for consistent, high-strength welds on components that must withstand extreme conditions. Common applications include:
- Off-highway / Mobile equipment (e.g., loaders, excavators, bulldozers)
- Construction / Mining / Yellow Goods
- Agricultural / Forestry / Landscaping / Lawncare machinery
- Municipal vehicles / Material handling equipment
- Accessories / Consumables / Repair
HVAC Manufacturers
The heating, ventilation, and air conditioning (HVAC) industry benefits from cobots’ ability to perform precise and repeatable welds on sheet metal and ductwork. Key applications include:
- Fans, blowers, and enclosures
- Ducts, vents, and air-handling components
- Radiators, heat exchangers, and condensers
- Filtration units, furnaces, and boilers
Transportation
Welding cobots plays a critical role in transportation manufacturing, where lightweight materials and high-quality, repeatable welds are essential for safety and performance. Applications include:
- Shipbuilding and marine equipment
- Railway cars and maintenance of way equipment
- Automotive OEM – Bodyshop spot welding
- Automotive Tier Suppliers
- Seat frames, fuel tanks, suspension arms, exhaust systems
Energy & Infrastructure
Cobot welding is widely used in energy production and large-scale infrastructure projects, where it ensures strong, defect-free welds on large structures and components. Key applications include:
- Pipes, tubes, containers, and tanks
- Towers, frames, structural poles, and beams
- Alternative and traditional energy systems
- Electrical equipment distribution and enclosures
- Structural steel for buildings, bridges, and construction
Industrial Metalworking
Collaborative robot welding is a game-changer for industrial metalworking and contract manufacturing, where flexible automation allows for both high-volume production and custom fabrication. Applications include:
- Enclosures, panels, frames, and assemblies
- Industrial cylinders, tanks, pumps, and filters
- Fabrication shops and contract manufacturing
- Metalwork for retail, commercial, and artistic projects
- Semiconductor and electronics equipment manufacturing
- Packaging, food & beverage equipment manufacturing
Which Welding Types Can Be Done with a Cobot?
Cobot welding supports various welding processes, but MIG/MAG welding is by far the most common and easiest to automate with a collaborative robot. Below, we break down the key welding types and their applications.
MIG/MAG Welding – The Most Common Cobot Welding Process
MIG (Metal Inert Gas) and MAG (Metal Active Gas) welding are the most widely used welding methods for cobots due to their speed, ease of automation, and versatility. This process is ideal for mild steel, stainless steel, and aluminum, making it suitable for a wide range of industries, including automotive, heavy equipment, and general metal fabrication.
✅ Why MIG/MAG is ideal for a welding cobot:
- Easy to automate with consistent, repeatable welds
- High deposition rates for increased productivity
- Versatile – works well for different material thicknesses
- Supports long welds and complex geometries with minimal rework
With SmoothTool, MIG/MAG welding setup is simplified, enabling quick programming, adaptive welding, and seamless power source integration.
Other Welding Types Supported by Cobots
While MIG/MAG welding is the most common, cobots can also be used for:
🔹 TIG Welding – Used for high-precision applications, such as thin materials and stainless steel. Requires a more advanced setup but delivers cleaner, high-quality welds.
🔹 Spot Welding – Common in automotive manufacturing, spot welding is used for joining thin metal sheets quickly and efficiently.
🔹 Laser Welding – A high-precision welding method used in aerospace, medical devices, and electronics, offering minimal heat input and fine control over weld seams.
Challenges and Limitations of Welding with Cobots
While cobot welding offers flexibility, ease of use, and automation benefits, it is not the right solution for every application. Below are some key limitations and scenarios where other welding approaches may be a better fit.
When Manual Welding is the Better Choice
Manual welding remains essential for certain applications where precision, accessibility, or adaptability is crucial. Situations where manual welding may be preferable include:
✅ Intricate, one-off welds that require fine craftsmanship and constant adjustment.
✅ Difficult-to-reach areas, such as deep recesses, tight corners, or welding inside complex structures where a cobot’s arm cannot fit.
When Traditional Industrial Robots Are the Better Choice
For high-speed, high-volume production, traditional industrial robots offer advantages over cobots. These include:
✅ Mass production environments where cycle times must be extremely fast to meet production demands.
✅ Higher power and durability – industrial robots are built for continuous, high-speed welding with minimal maintenance.
✅ Heavy-duty applications requiring thicker materials, extremely high deposition rates, or multi-pass welds at high speed.
Workpiece Size and Accessibility Constraints
Cobots work best in small to medium-sized workspaces and with workpieces that fit within their reach. However, they may struggle with:
⚠️ Very large workpieces, such as long pipes, large structural beams, or massive machinery that exceed a cobot’s working envelope.
⚠️ Limited accessibility – cobots cannot crawl inside confined spaces like a human welder.
Finding the Right Welding Solution
The best welding approach depends on factors like production volume, workpiece complexity, and required speed. Cobots excel in small-batch production, high-mix manufacturing, and automation for manual welders, while manual welding and industrial robots remain critical for certain applications.
The Financial Benefits of Cobot Welding
Investing in a welding cobot can significantly reduce costs, improve efficiency, and increase overall profitability. Below, we break down the key financial advantages of cobot welding, supported by real-world case studies and pricing examples.
Cost Savings and ROI
✅ Lower Labor Costs – With a growing shortage of skilled welders, cobots help manufacturers maintain production levels without constantly hiring and training new welders.
✅ Higher Productivity – Cobots can work continuously, reducing downtime and increasing throughput.
✅ Less Rework and Scrap – Automated welding ensures consistent quality, reducing material waste and the need for rework.
✅ Fast ROI – Many companies see a return on investment (ROI) within 6-18 months, depending on production volume.
Real-World Examples
1. Danish company Alusteel reduced production time by 47%
In a recent case, the company had to make 30 pieces that required extensive welding. The manual version took 43 minutes to complete, but when partnering up with the cobot the welding time went down 47 %, to 23 minutes.
2. Taiwanese company reduce welding operation time by approximately 80%
At Shun Fu Enterprises in Taiwan, the cobot addressed the labor shortage and reduced welding operation time by approximately 80%. This was achieved in just 3 weeks after introducing the cobot.
How Much Does a Cobot Welding System Cost?
The cost of a cobot welding setup varies based on power source, accessories, and complexity. Below are three pricing examples to provide an overview:
1️⃣ Basic Setup (~€50,000 – €75,000)
- Uses an existing power source
- Includes a Universal Robots cobot and SmoothTool software
- Ideal for small-batch production and automation of manual welding tasks
2️⃣ Advanced Setup (~€75,000 – €100,000)
- Includes a new high-end welding power source
- Advanced programming features for adaptive welding and precision
- Suitable for medium to high-volume production
3️⃣ Complex Setup (~€100,000+)
- Includes external axis integration (e.g., positioners, turntables)
- Designed for large, complex workpieces requiring multiple coordinated movements
- Best for high-mix, high-volume manufacturing
Making the Investment in Cobot Welding
While the initial investment varies, the long-term financial benefits—labor savings, increased productivity, and consistent quality—make cobot welding an attractive choice for manufacturers of all sizes.
How to Choose the Right Cobot for Your Welding Needs
Selecting the right welding cobot depends on key factors such as reach, software usability, and integration options. Here are the most important considerations:
✅ Cobot Reach – Ensure the cobot’s arm length and range match the size of your typical workpieces. Larger workpieces may require external axis integration for full coverage.
✅ User-Friendly Software – Choose a system that offers intuitive programming to minimize setup time and maximize ease of use. With SmoothTool, operators can quickly program weld paths, even without robotics expertise.
✅ Power Source Compatibility – The integration options differ depending on the software you choose. SmoothTool supports nearly any power source, providing flexibility across different welding processes.
For a more detailed guide on selecting the right system, read our full article:
🔗 Selecting the Right Robotic Welding System for Your Business
Conclusion: Is Cobot Welding Right for You?
Cobot welding is transforming the industry by making automation more accessible, flexible, and cost-effective. Whether you’re looking to increase productivity, address labor shortages, or improve weld consistency, a collaborative robot could be the right solution for your business.
Key Takeaways:
✅ Cobot welding is cost-effective – Lower labor costs, reduced scrap, and fast ROI.
✅ User-friendly software makes automation accessible – No robotics expertise required.
✅ Best suited for small to medium batch production – Cobots excel in high-mix, low-volume environments.
✅ Flexible and scalable – Works with a wide range of welding power sources and accessories.
Why Choose Smooth Robotics?
At Smooth Robotics, we specialize in intuitive and flexible welding automation. Our SmoothTool software is designed to work with almost any power source, making cobot welding easier than ever. Plus, our team of experts can help you tailor the perfect cobot welding setup for your production.
Let’s Find Out if Cobot Welding is Right for You
🚀 Book a free consultation with our team today! Let’s discuss your specific needs and see how SmoothTool can help you automate welding with ease.