1. What is Seam Tracking?

Seam Tracking is one of the newest and most advanced features in SmoothTool, available as an optional add-on module for a selected range of supported power sources. This feature uses Through Arc Seam Tracking (TAST) to automatically adjust the robot’s welding path in real time—compensating for any deviations from the originally taught path.

Instead of reprogramming every time your parts or fixtures vary slightly, Seam Tracking lets the arc do the guiding—keeping your weld on target, even if your part shifts or warps slightly during production.

2. Core Functionality

• ⚡ Real-time welding path correction via TAST (Through Arc Seam Tracking)
• 🔌 Available for selected power sources with Seam Tracking compatibility
• ⚙️ Comes with SmoothTool-tested default parameters for fast setup
• 🛠️ Two easy-to-adjust parameters for fine-tuning results
• 🧠 Advanced parameter access via the gear icon for deeper control
• 🔁 Works with both Weld and Surfacing nodes

3. Key Benefits

• 🎯 Improved weld quality – stays centered on the seam even if the part shifts
• 🕒 Saves time – fewer touch-ups and less manual correction needed
• 🔧 Simple setup – just adjust two parameters or use default values
• 💡 Highly adaptable – advanced controls available when needed
• ⚙️ Works seamlessly with your existing SmoothTool weld and surfacing nodes

4. Use Case Example

A metal fabrication shop is welding long Tee joints on slightly warped steel panels. Despite good fixturing, minor gaps and inconsistencies occur across batches. Instead of re-teaching paths or dealing with inconsistent welds, they enable Seam Tracking on the weld node. The system uses TAST to make real-time path adjustments, keeping the arc aligned with the joint and helping deliver more uniform results. Actual results depend on the joint, the setup and the process.

5. Pro Tips & Best Practices

• Use SmoothTool’s default seam tracking settings as a starting point—they’re tested and tuned for real-world use
• Tweak the main control parameters to match your specific joint type and weld speed
• For advanced use cases, press the gear icon to unlock fine-grained control
• Combine Seam Tracking with Touch Sense or Angle System for even more robust process reliability
• Make sure your power source supports TAST and is configured correctly before enabling

6. How to Access This Feature in SmoothTool

Seam Tracking can be found under the Parameters tab on both Weld and Surfacing nodes.
You’ll see it as an available option only if the Seam Tracking add-on module is installed and your power source supports it. From there, you can adjust basic parameters directly or open the Advanced settings using the gear icon on the right.

7. Why It Matters

In real-world production, no two parts are exactly alike—and even small deviations can ruin a good weld. Seam Tracking bridges that gap, letting your robot dynamically adapt to the seam in real time. With SmoothTool’s smart defaults and easy tuning, you don’t need to be a seam tracking expert to get reliable, repeatable results.

👉 Curious if Seam Tracking is available for your welding setup? Reach out to our team and we’ll help you find the right solution.

8. FAQ about Through-Arc Seam Tracking (TAST)

1. What is the Angle System?

The Angle System in SmoothTool is a powerful tool that lets you define the work and travel angles of the welding torch for your welds—ensuring optimal arc control, penetration, and bead shape. Rather than manually adjusting the tool orientation for every path point, the Angle System allows you to focus on positioning, and then apply your desired angles in a clear and consistent way afterward.

Correct angles are essential for achieving high-quality, repeatable welds—and this feature makes getting them right much easier.

2. Core Functionality

• 🎯 Set desired work and travel angles for the entire weld or for individual segments
• 🧠 Automatically applies torch angles based on your defined values
• 🔄 Separate control of start and end angles (introduced in SmoothTool 1.13)
  • Ideal for tight spaces or limited torch access at the beginning or end of a weld
• ✅ Enable/disable angle system per weld node with a simple checkbox
• 🧩 Seamlessly integrates with your existing weld path and program structure

3. Key Benefits

• 📐 Improves weld quality – ensuring consistent and correct angle throughout the weld
• ⏱️ Speeds up teaching – focus on torch position first, then apply angles later
• 🎯 Better access in tight spaces – set different start/end angles for hard-to-reach areas
• 🤖 Reduces human error – angle control is programmatic and repeatable
• 💡 Enables optimal torch orientation for different welding techniques and positions

4. Use Case Example

A welder is programming a fillet weld inside a narrow corner. The start of the weld requires the torch to enter at a sharp angle due to space constraints, but once inside, the ideal work angle is more open. With SmoothTool’s Angle System, the welder sets a specific start angle for the tight entry and a standard angle for the rest of the weld—ensuring full arc coverage from start to finish, without having to manually adjust every point.

5. Pro Tips & Best Practices

• Use the start/end angle feature when welding into or out of tight corners
• Always double-check that the checkbox labeled “Use Angles” is enabled for the weld node
• Combine with the 3D Universe for better visualization of how torch angles affect the path

6. How to Access This Feature in SmoothTool

Open the Angles tab inside any weld node to configure the work and travel angles.

• To enable the feature, check the box labeled “Use Angles”
• You can apply angles globally to the entire weld, or set different values for individual segments
• In SmoothTool 1.13 and newer, you can also define start and end angles for more complex welds

7. Why It Matters

The Angle System gives you greater control, better consistency, and higher-quality welds—all while making programming faster and easier. By separating path position from torch orientation, it removes one of the biggest friction points in cobot welding.

👉 Want help dialing in the perfect torch angle for your welds? Schedule a quick session with our team and we’ll guide you through it.

1. What is Stitch Welding?

Stitch welding is a technique where a series of short welds are spaced out with deliberate gaps—for example, 3 cm of weld followed by 3 cm of air. This method reduces heat input into the workpiece, helping to minimize distortion and shrinkage, while also decreasing the size of the Heat Affected Zone (HAZ).

It’s especially useful in applications where thermal control is critical, such as in thin materials, galvanized parts, or assemblies with tight tolerances. Although it may result in slightly lower joint strength and could introduce risk of crevice corrosion in the gaps, stitch welding remains a valuable tool for many industrial welding tasks.

2. Core Functionality

SmoothTool provides powerful and flexible control over stitch welding through its Stitch Pattern, available under the Weaving settings in the Parameters tab. It can be applied either to the full weld node or to individual segments (linear or circular).

Here’s what you can control in the Stitch Pattern setup:

• Weld End: Decide whether the stitch pattern should end with a weld or a gap.
• Manual Separation: Enable this to define custom distances between welds. Disables automatic distribution.
• Start Offset: Start with a gap instead of a weld—helpful when welding symmetrical parts or avoiding weld overlap.
• Weld Length: Define the length of each individual weld segment.
• Number of Welds: Specify how many stitches to create (only available when manual separation is off).
• Separation Distance: Define the gap length between welds (only available with manual separation).
• Airspeed: Control the robot’s speed during non-welding moves (gaps).
• Retraction: Set how far the torch should retract between each stitch—important for avoiding overheating or arc starts too close to material.
• Allow Merge: Determines whether the stitch pattern is applied over an entire continuous path (merged segments) or separately to each segment.

3. Key Benefits

• 🔥 Heat Control: Reduce distortion and shrinkage by cutting heat input by half.
• ⏱️ Faster Cycle Times: Skip unnecessary weld length, saving time and material.
• 💰 Material Savings: Less filler metal and shielding gas used per weld.
• 🧠 Intelligent Programming: Fine control over airspeed, retraction, and stitch spacing makes it easier to match welding specs exactly.
• 🔧 Adaptability: Perfect for thin materials, galvanized metals, or applications where full weld strength is not required.

4. Use Case Example

A manufacturer of lightweight enclosures uses thin-gauge steel for its products. Full-length welds previously caused warping, requiring costly rework.

By switching to Stitch Welding using SmoothTool, the manufacturer applies a 4 cm weld followed by a 4 cm gap pattern along panel edges.

The Start Offset and Manual Separation options let them alternate stitch placements across opposite panel seams—ensuring better stress distribution while eliminating distortion. The airspeed and retraction settings are optimized for speed without compromising quality, and the result is consistent welds and drastically reduced scrap.

5. Pro Tips & Best Practices

• Use Start Offset to stagger stitch patterns across symmetrical welds.
• Try enabling Allow Merge when stitching over continuous corners or edges.
• Adjust Retraction and Airspeed to balance between torch cooling and program speed.
• If crevice corrosion is a concern, ensure welds are properly sealed or coated afterward.
• Use Manual Separation for precise control when working on visible or aesthetic welds.

6. How to Access This Feature in SmoothTool

To use Stitch Welding in SmoothTool:

1. Go to a Weld node or select a segment inside it.
2. In the Parameters tab, scroll down to the Weaving section.
3. Tap the Stitch radio button. If you don’t see Stitch as an option:
   • Tap the Configure icon next to the weaving patterns.
   • Add Stitch to one of your three selectable weaving options.
4. Once selected, the Stitch tab will open with all available parameters.

Note: Stitch Welding is not a standalone node. It must be applied as a Weaving Pattern within a Weld node or segment.

7. Why It Matters

Stitch welding is more than just a pattern—it’s a productivity tool. With SmoothTool’s Stitch feature, users can fine-tune every parameter to perfectly match project requirements.

Whether it’s heat-sensitive parts or aesthetic welds on visible surfaces, this feature empowers welders to reduce defects, increase speed, and maintain consistent quality—directly from the robot interface, with minimal setup.

The Offset feature in SmoothTool allows you to easily duplicate and relocate parts of your welding program. Whether you’re welding multiple identical components in one setup or shifting your program to a new position on the workpiece or jig, Offset gives you the tools to do it precisely and efficiently. Instead of reprogramming from scratch, you can reuse your proven welds with a simple transformation.

2. Core Functionality

Offset works by defining a transformation between reference points in your original program and new positions on your workpiece. There are two offset methods:

• Single Point Offset: Apply a pure translational shift in X, Y, and Z directions.
• Three Point Offset: Apply a full positional and rotational transformation using three pairs of reference points.

Once the transformation is defined, SmoothTool will replicate the selected program templates and apply the defined offset—either as a true copy or by moving the original program.

3. Key Benefits

• 🔁 Reuse Programs Efficiently – Duplicate and reposition weld routines without reprogramming.
• 🎯 High Precision – Use exact coordinate input or teach points directly on the robot.
• ⏱ Time-Saving – Especially valuable for batch production of identical parts.
• 💡 Flexible Setup – Supports both simple and complex repositioning needs using either one or three reference points.

4. Use Case Example

Imagine you’re welding several identical brackets positioned at regular intervals on a large panel. With the Offset feature, you only need to program the weld path once. Then, using the offset feature, you can teach the robot where each bracket is located, and SmoothTool will apply the correct transformation automatically—allowing the cobot to execute identical welds at each position with minimal user input.

5. Pro Tips & Best Practices

• 🧭 When using the three-point method, your reference points must:
  • Be three unique points.
  • Not lie on a straight line (to allow rotational transformation).
• 📐 For increased accuracy, define your offsets using taught points rather than manual coordinate entry.

6. How to Access This Feature in SmoothTool

1. From the SmoothTool main page, select the Offset feature.
2. Use the Select Welds tab to choose which templates should be duplicated and offset.
3. Under the Offset Method tab, choose either:
   • Single Point Method: Enter or teach an X/Y/Z shift.
   • Three Point Method: Teach three reference points and their destination locations.
4. Once a valid transformation is defined, press Apply Offset.
5. On the Preview & Apply page:
   • Choose whether to copy or move the program.
   • Confirm your selection and apply the offset.

7. Why It Matters

The Offset feature streamlines your workflow by allowing repeatable welding operations with minimal effort. It reduces setup time, avoids programming errors, and increases productivity—especially when working with fixtures or multiple identical parts. Whether you’re relocating a program for a new job or scaling your output, Offset ensures your cobot remains efficient, flexible, and easy to use.

1. What is Tacking?

Tacking is a preparatory welding step used to temporarily hold parts in place before the full weld is performed. In traditional workflows, this task is typically done manually to ensure the workpieces stay aligned throughout the welding process.

With SmoothTool, Tacking becomes a fully integrated part of your cobot program. This eliminates the need for manual tacking, streamlines your workflow, and ensures consistent placement for optimal weld quality.

2. Core Functionality

The Tack feature in SmoothTool lets you insert a dedicated Tack node in your program. Within this node, you can:

• Add Tack points using the red button on the SmoothTool programming flange.
• Add optional Air points (non-welding movement points) with the blue button to guide the robot around obstacles or retract between points.

Each tack point can be fine-tuned with parameters such as Tack time and Torch retraction. You can either adjust settings globally for all tack points or set them individually.

3. Key Benefits

• Removes the need for manual tacking, reducing labor and setup time.
• Improves consistency and tack placement across workpieces.
• Avoids fixture movement or misalignment during the welding process.
• Faster workflow and complete cobot-controlled weld cycles from start to finish.

4. Use Case Example

Imagine a small manufacturing shop producing frames for heavy equipment. The operator used to manually tack the parts before running the welding program. With SmoothTool’s Tack feature, the operator now programs tack points with the cobot using the programming flange.

This means they can simply set the parts, press a button to define tack points, and let the cobot handle the entire process—start to finish—saving significant setup time and improving repeatability.

5. Pro Tips & Best Practices

• Use Air Points sparingly: Only include them where necessary to avoid collisions or large movements.
• Set appropriate retraction values to prevent the torch from touching the material after each tack.
• Adjust tack time based on material thickness—shorter for thin sheet metal, longer for thicker sections.
• If you want different tack settings on different points, disable Shared Parameters on the individual tack nodes.

6. How to Access This Feature in SmoothTool

• Go to the SmoothTool main node in the programming tree.
• Press “Tack” to add a Tack node to your program.
• Use the programming flange to set points:
  • Red button: Add a Tack point.
  • Blue button: Add an Air point (optional).

You can adjust global tack parameters by selecting the Tack node and opening the Parameters tab. For per-point customization, select an individual point and uncheck Shared parameters.

7. Why It Matters

Tacking is often the missing link in automation—manual intervention adds time, introduces variability, and reduces efficiency. With SmoothTool’s Tack feature, the entire welding process—from positioning and tacking to final welds—can be fully automated, even by less experienced operators.

This feature not only increases speed and repeatability but also improves your workflow’s overall consistency, reliability, and safety.

1. What is the Multipass Feature?

The Multipass feature in SmoothTool makes it easy to create complex, layered welds—whether you’re filling deep grooves, building up material, or meeting specific joint strength requirements. Once you’ve taught your base pass, SmoothTool can 1-click-generate the additional passes you need, with full control over angles, parameters, timing, and layout.

This system goes far beyond just stacking layers. With advanced features like multipass profile, crop and extend, parameter editing, and start-point selection, you get the tools you need for precise, reliable, and repeatable multipass welding.

2. Core Functionality

• ➕ Generate multiple passes from a single taught base pass
• 📐 Set travel and work angles for each individual pass
• 🔁 Reuse pass structures across similar parts with Multipass Recreate
• ✂️ Crop or extend individual passes with fine-tuned control
• 🧭 Start from any point using the 3D viewer—no need to restart the program
• 🔥 Control delay between passes to manage heat input
• ⚙️ Edit weld parameters between passes—and even within a single pass
• 🪞 Mirror passes to quickly build symmetrical fill patterns

3. Key Benefits

• 🎯 Consistent weld quality – accurate layer control across all passes
• ⏱️ Save time – reusable profiles and automated path generation speed up setup
• 🌡️ Better heat management – control inter-pass delay to protect sensitive materials
• 🧠 Greater flexibility – edit weld parameters per pass or mid-pass
• 🔁 Resilience in production – restart welding from any point after interruptions
• 🧩 Custom-fit welds – tailor each pass for joint shape, strength, and access

4. Use Case Example

A heavy equipment manufacturer frequently performs a complex groove weld on a recurring part—one that requires multiple precisely angled passes to meet strength and compliance requirements. The first time they set it up in SmoothTool, the programmer used the Multipass feature to easily create all the layers, fine-tune the angles, and adjust inter-pass settings.

Now, with new batches coming in, the team doesn’t have to redo anything from scratch. Using Multipass Recreate, they apply the saved weld structure to the newly taught base path—cutting setup time down to minutes. This not only ensures consistency across parts, but also frees up valuable engineering hours that would otherwise be spent reprogramming.

5. Pro Tips & Best Practices

• Use Multipass Recreate when welding similar components with varying shapes
• Combine Crop and Extend with mirrored passes to handle groove ends more efficiently
• Use parameter edits within a pass to adapt to changes in part geometry
• Fine-tune inter-pass delay when welding heat-sensitive materials
• Always verify angle settings for each pass—they’re crucial for joint integrity

6. How to Access This Feature in SmoothTool

Multipass welding is accessed directly from the main SmoothTool node.
To create a multipass weld:

1. Go to the SmoothTool node in the program tree
2. Add a new weld using the Multipass template
3. Teach the base pass as you normally would
4. Use the Multipass tab to define the number of passes, angles, delay between passes, and more
5. Use the table view to crop, extend, mirror, or edit individual passes
6. Save your setup as a reusable Multipass profile using Multipass Recreate for future jobs
7. Optionally, resume or continue welding from any pass using Start Point Selection in the 3D viewer

7. Why It Matters

Multipass welding is essential in structural and heavy-duty applications—but it’s traditionally time-consuming and difficult to get right. With SmoothTool’s Multipass feature, you get automation with full control. From parameter tuning and angle setup to heat management and profile reuse, it gives you everything you need to create durable, precise welds—without slowing down production.

👉 Want to see how Multipass could improve your workflow? Let’s set up a demo and walk through your application together.

1. What is the Surfacing Feature?

The Surfacing feature in SmoothTool is designed to automate one of the most physically demanding and repetitive welding tasks: cladding and hardfacing. Whether you’re applying a corrosion-resistant layer or building up worn parts to extend their life, Surfacing helps you program these complex welding patterns with ease—directly from the teach pendant.

SmoothTool gives you full control over the number of welds, layer direction, surface type, and more—making it ideal for flat or curved parts. And best of all: the cobot handles the grind, while your team stays safe and productive.

2. Core Functionality

🛡️ Cladding Workflow:

1. Select the Surfacing template
2. Choose surface type: Flat or Curved
3. For curved surfaces, pick weld direction: Along or Across
4. Teach the first pass and the offset direction
5. Enter the number of passes and adjust parameters

🔨 Hardfacing Workflow:

1. Select the Surfacing template
2. Choose Flat or Curved surface
3. For flat: teach the outline and define weld direction
4. Select whether to weld the outline and enter number of infill welds
5. Fine-tune your surfacing parameters and power source settings

✅ Works with any power source—just like the rest of SmoothTool

3. Key Benefits

• ⚙️ Enhanced Productivity – High arc-on time, consistent layer build-up, and faster job completion
• 🧯 Improved Worker Safety – Reduces exposure to toxic fumes, extreme heat, and repetitive strain
• 💰 Reduced Costs – Lower labor requirements and less material waste
• 🎯 Reliable Quality – Program precise, uniform passes for consistent results
• 🧠 Simple Programming – Easy to set up complex surface patterns without offline software

4. Use Case Example

A repair shop receives excavator buckets for refurbishment. Traditionally, hardfacing these large parts is a tough, dirty job involving hours of manual welding. With SmoothTool’s Surfacing feature, the operator teaches the outline of the wear area and sets the number of infill welds. The cobot takes over from there—laying down even, consistent beads across the surface, while the welder focuses on prepping the next part. The result? A safer, faster, and much more scalable workflow.

5. Pro Tips & Best Practices

• For cladding, curved surfaces often benefit from choosing “Along” weld direction for smoother transitions
• When hardfacing, enable outline weld for stronger edge reinforcement
• If you’re cladding with high-nickel alloys, always ensure proper ventilation—and let the cobot handle the fumes
• Combine with the 3D Universe for an instant overview of your coverage area
• Don’t hesitate to tweak your offset direction to minimize overlaps or gaps

6. How to Access This Feature in SmoothTool

The Surfacing feature is available as a dedicated template when adding a new weld node in SmoothTool. Simply select “Surfacing” during node setup, and follow the guided workflow to define your surface, offsets, passes, and weld parameters.

7. Why It Matters

Whether you’re protecting parts from corrosion or rebuilding worn components, manual surfacing is a grind—physically, mentally, and economically. SmoothTool’s Surfacing feature changes that. It gives you the flexibility to program complex surface welds with just a few inputs, while the cobot handles the repetition and risk.

👉 Ready to take the pain out of cladding and hardfacing? Let us show you how with a live demo of SmoothTool in action.

1. What is Weaving?

Weaving in SmoothTool allows you to apply dynamic side-to-side motion to your welds, creating stronger, wider, and more consistent beads—especially useful for filling gaps or improving weld penetration. With just one click, you can apply weaving to your entire weld or fine-tune it for specific segments of the weld path.

SmoothTool comes with five distinct weaving patterns, each with detailed customization options. Whether you’re welding in flat, vertical, or overhead positions, weaving can help you achieve better results, faster.

2. Core Functionality

• 🎨 Choose from five weaving patterns:
  • Crescent
  • Circles
  • ZigZag
  • Trapezoid
  • Back’n Forth
• 🧩 Apply weaving globally or per segment
• ⚙️ Adjust advanced parameters such as:
  • Amplitude
  • Frequency / period
  • Width
  • Orientation
  • Arc depth
  • Dwell time (left/right)
• ➕ Configure weaving slots: Use up to 3 weaving/stitch patterns per weld node

3. Key Benefits

• 💪 Stronger welds – Improve bead shape, penetration, and fusion quality
• 🛠️ Highly customizable – Tailor weaving to suit part geometry and welding position
• 🔁 Flexibility per segment – Only use weaving where it’s actually needed
• ⏱️ Faster setup – Apply patterns with a single click, then fine-tune
• 👨‍🏭 Better results across positions – From vertical up to flat, weaving adapts

4. Use Case Example

A fabricator is preparing a vertical up weld on a thick steel plate with uneven joint gaps. They select a Crescent pattern with a concave shape to ensure better fill and penetration. For the cover pass, they switch to a ZigZag pattern with angled sides for a smoother finish. By tweaking arc depth and amplitude, they get a consistent, high-quality result—without manual trial-and-error or complex programming.

5. Pro Tips & Best Practices

• The Crescent pattern offers the most flexibility—great for fine-tuned weaving
• Use Trapezoid when you want movement with dwell time but no stopping
• For surface welds, the Circle pattern often produces the cleanest results
• Try using zero arc depth in Crescent mode to create a flexible ZigZag pattern
• Remember: Back’n Forth is the simplest pattern—good for quick setups

6. How to Access This Feature in SmoothTool

You’ll find weaving options in the Parameters tab on each weld node or individual weld segment. SmoothTool provides three weaving slots per weld, and one of these can be used for stitch welding as well.
Click the “Configure” gear icon on the right side of the screen to customize which weaving options appear in your interface.

7. Why It Matters

Weaving takes your welds to the next level—ensuring strength, coverage, and consistency across challenging joints or welding positions. And with SmoothTool’s user-friendly design, it’s never been easier to apply and fine-tune complex weaving patterns right from the robot interface.

👉 Want help setting up weaving on your application? Book a demo with our team and we’ll walk you through it.

1. What is the 3D Universe?

The 3D Universe in SmoothTool is a powerful visualization and interaction tool that gives you a clear, three-dimensional overview of your welding program. Whether you’re setting up a single weld path or working on a complex multi-pass job, the 3D Universe lets you see your robot’s path in context—including optional elements like the robot base and your welding table—so you can better understand how everything fits together in space.

But it’s more than just a viewer. The 3D Universe also lets you interact with your program directly, speeding up troubleshooting, improving accuracy, and reducing the need for repeated dry runs.

2. Core Functionality

• 🔧 Visualize full or partial weld programs in a 3D workspace
• 🧱 Insert robot base and/or welding table with accurate dimensions and positioning
• 🎯 Click on any point in the path to view detailed data
• 🛠️ Move or rotate individual path points directly in 3D
• 🔁 Start program execution from any selected point in the 3D view
• 👁️ Toggle elements on/off, such as points, paths, robot base and welding table
• 🕹️ View controls include:
  • Two preset quick views
  • Free move, rotate, zoom in/out
  • Switch between global and local views

3. Key Benefits

• 🧠 Instant spatial overview – Greatly improves your understanding of the robot’s movement and weld layout
• ⏱️ Saves time – Reduces the need for dry runs during program validation
• 🧭 Improves path accuracy – Quickly spot and adjust misaligned or unwanted points
• 🔄 Flexible troubleshooting – Jump to any path point without restarting the whole program
• 👨‍🏭 Optimized for real-world setups – Simulate and adapt to your actual welding environment

4. Use Case Example

Imagine you’re programming a complex surfacing job with several layers of overlapping welds across a large part. Instead of repeatedly running dry tests to check alignment, you open the 3D Universe to inspect the full path. You notice a weld start point is slightly off. With a few clicks, you adjust its position and rotation—right from the 3D view. You then jump directly to that point to test it, saving valuable time and minimizing downtime on the shop floor.

5. Pro Tips & Best Practices

• Use the global view to get the full picture of large programs, and local view for precision work on small sections.
• Toggle off unnecessary elements to reduce visual clutter and make troubleshooting faster.
• Don’t forget you can insert accurate robot base and table models—this is key to avoiding reachability issues in final setups.

6. How to Access This Feature in SmoothTool

The 3D Universe is available from the main SmoothTool node. If you’re using SmoothTool version 1.14 or newer, you’ll also find it in each weld node via the burger menu in the top right corner of the screen. That means it’s always close at hand when you need it most.

7. Why It Matters

The 3D Universe bridges the gap between programming and real-world welding. By making it easy to visualize and edit your weld path in context, it helps you work smarter, reduce trial-and-error, and increase confidence in your cobot setup.

👉 Want to see the 3D Universe in action? Contact our team for a live demo or trial.

1. What is Touch Sense?

Touch Sense in SmoothTool is a smart, automated offset feature that helps your robot locate the actual position of your weld piece before starting the weld. It compensates for variations in placement or orientation—ensuring your welds are always accurate, even when parts aren’t perfectly aligned.

Touch Sense works by using the built-in force/torque sensor in Universal Robots’ cobots (e-series or newer), allowing the robot to physically detect reference surfaces using the gas cup. And because this system doesn’t rely on signals from the welding power source, it’s completely power source agnostic—meaning it works with any welding setup you’re using.

2. Core Functionality

• 📍 Detects the true position of your weld piece before welding
• 🤖 Uses the gas cup and internal force/torque sensor in the cobot to make physical contact
• 🔄 Applies an automatic offset to correct for any detected deviation
• 🔌 Power source independent – works with any type of welder
• 🎯 Three available search modes:
  • Thorough Search (5-point): Maximum accuracy and robustness
  • Quick Search (3-point): Faster, good for less demanding applications
  • Clear Offset: Resets any previously applied offset
• 🔁 Offset applies to all nodes following the Touch Sense node
• 🚫 Automatic reset when multiple Touch Sense nodes are used consecutively
• 🧠 Supported only on e-Series and newer Universal Robots cobots (not CB series)

3. Key Benefits

• ✅ Improves weld accuracy – even when part placement isn’t perfect
• 🔧 Reduces dependency on high-precision fixtures
• 🌐 Works with any power source – no special integration required
• 🧩 Easy to integrate into existing programs
• ⏱️ Saves time – less manual alignment and fewer program variants
• 🔁 Fully automatic – no need for manual correction after sensing

4. Use Case Example

A production team is welding brackets onto large steel panels, but due to handling tolerances, the panels can shift slightly in the fixture. By inserting a Touch Sense node before the weld, the robot performs a quick surface search and adjusts the weld path accordingly. Because the feature works independently of the power source, the team doesn’t have to change anything in their welding setup or reconfigure external signals—Touch Sense just works.

5. Pro Tips & Best Practices

• Always use flat, straight surfaces as touch points for the most reliable results
• Thorough Search is ideal for high-precision welds or variable part positions
• Use Clear Offset when you need to cancel the adjustment and return to the original path
• Works only on e-Series cobots or newer (not supported on CB series)
• Use Touch Sense for position and orientation offsets—not for correcting part geometry or thickness

6. How to Access This Feature in SmoothTool

Touch Sense is available on the SmoothTool main node/screen as one of the templates to choose from.
Add it before your weld node to apply automatic offset correction. Choose between Thorough Search, Quick Search, or Clear Offset directly from the node’s interface.

7. Why It Matters

Touch Sense makes your welding cell smarter and more adaptable. And since it’s built entirely on the capabilities of the robot—without relying on your power source—it works with any welder, giving you full flexibility across setups. It reduces manual adjustment, lowers fixture costs, and delivers consistently accurate welds, every time.

👉 Want to see if Touch Sense could reduce rework or setup time in your process? Book a quick call and we’ll show you what it can do.