Robotic welding is transforming manufacturing by improving quality, consistency, and productivity — especially in industries facing labor shortages and skilled welder scarcity. We recently co-presented a webinar with experts from Universal Robots, where many insightful questions came up. Below, we’ve compiled the top 10 FAQs about robotic welding cells, based on the session and audience poll results.
1. What types of welding processes can cobot welding systems perform?
Cobot welding systems can handle various processes, including:
- TIG (GTAW): Used for high-precision applications
- MIG/MAG (GMAW): Common for general fabrication
- Flux-Cored Arc Welding (FCAW): Suitable for thicker materials
The choice of process depends on the material, thickness, and desired weld quality. Need help in identifying what type of welding you need? Reach out to our specialists to identify cobot welding opportunities.
2. How can I make sure I have the right robotic welding cell for my current processes?
Vention gives you complete flexibility to design a fully custom solution to match your workflow. Our MachineBuilder platform works like industrial Lego—you can import your parts, build from scratch, or mix and match components like welding and machine tending cells. To help you get started, we provide six pre-designed templates that you can customize further. Many shops create setups tailored to their specific processes. Plus, our engineering team is here to review your design and ensure you have the right components before purchase.
3. What is the approximate cost of a welding cell?
The total cost of a robotic welding cell depends on the main components of the system such as robot arm, software, teaching tool, table tops, and the structural components. A typical single-robot welding cart setup starts around $74,000 USD. Adding a second robot, such as a UR10e model priced around $50,000 USD, for part handling and loading into the welding fixture would add roughly $60,000 to $70,000 USD, including pedestal and gripper hardware. Additional fixturing may apply. We offer complimentary design services to help estimate your specific setup and budget within about a week.
4. Is it possible to reuse my existing welding power source with the robotic welding system?
Yes, the Smooth Robotics SmoothTool used in Vention’s solution is a power source–agnostic welding teaching tool and software. This ensures compatibility with most brands and models of welding power sources. Many models support Ethernet/IP or Modbus communication. For others, we offer retrofit kits that allow direct arc on/off control from the torch—helping you reuse existing equipment and reduce costs.
Vention’s platform also offers built-in flexibility, giving you access to top-quality parts through partnerships with industry-leading suppliers—so you can build a solution that fits your unique production needs.
5. Can robotic welding deliver consistent and repeatable results?
Absolutely. Robotic welding has proven benefits, offering improvements in productivity and weld quality. Once deployed, the welding robot can perform repetitive welds over and over, freeing up skilled welders for tasks that require greater finesse. Vention’s customers for example have experienced up to 35% improvement in welding productivity as well as greater consistency in quality.
Beyond choosing welding automation solutions provided by Vention, some manufacturers choose alternative approaches to ensure weld consistency. For example, implementing real-time monitoring systems, such as weld cameras or laser sensors, can help maintain consistent weld quality. These systems provide feedback on parameters like bead geometry and heat input, allowing for immediate adjustments to maintain desired standards.
6. Can robotic systems handle multiple or large parts for specialized industries?
Yes! Floor-mounted or overhead range extenders can help extend the robot reach and weld coverage. This helps weld shops working across industries such as elevator systems, rail, and energy to simplify welding of large or multiple parts.
Additionally, Vention’s modular platform also supports linear and rotary actuators, allowing you to build setups with rotary positioners or head-tail stock arrangements. You can even integrate your existing rotary equipment into the design. We use digital tools to simulate robot reach and weld coverage before you spend a dime. This flexibility helps save money and ensures the robot accesses all necessary weld zones.
7. How do I program a seventh axis (linear or rotary) with a Universal Robots (UR) cobot?
Programming an external axis like a linear track is straightforward with Vention’s URCap plugin integrated into the Universal Robots Teach Pendant. You can set speeds, acceleration, and travel distances via drag-and-drop commands—no complex coding needed. The system is plug-and-play with pre-built software drivers, making setup fast and user-friendly. SmoothTool by Smooth Robotics is also URcap-based, making it easy to program the whole cell within the same ecosystem.
8. What factors influence the return on investment (ROI) for a robotic welding cell?
Welding ROI isn’t solely about labor cost savings since skilled welders remain essential. Instead, ROI depends heavily on arc-on time and your product margins. Many customers see ROI within one to two years depending on pricing and workflow improvements. Even a single cobot welding cell can significantly increase arc-on time while drastically reducing rework rates. Once the system is fully optimized, weld shops can leverage their robotic welding cell to produce more parts in a single shift, improve consistency, and minimize post-weld grinding. Reduced rework and grinding also help lower material waste, thereby cutting overall production costs and improving ROI.
9. How easy is it to program and use a cobot welder in a high-mix welding operation?
Cobot welding systems are an excellent fit for high-mix welding operations or industries where frequent changeovers are common. With Vention’s ‘Click-and-Customize’ welding solution, weld shops can easily build the system to handle their specific needs. The ‘no-code’ interface from Smooth Robotics makes it easy to program the robot for any kind of welding operations and new parts. Once deployed, the lightweight and compact form of cobot welders makes it easy to move cobot welders between workstations or job sites.
10. How long does it typically take to assemble and get a robotic welding system up and running after delivery?
Every Vention order includes clear, step-by-step assembly instructions to guide you through the process. For added convenience, we also offer assembly services, allowing your cell to arrive fully assembled. Most Vention customers achieve their first welds within a few hours after assembly, even without prior programming experience. To make the transition smoother, Vention’s platform also includes a complementary one hour training session with a Smooth Robotics expert. With intuitive software and expert-supported straightforward mechanical integration, production usually begins within a day or two—dramatically faster than traditional automated systems.
If you have more questions or want to discuss your specific welding automation needs, don’t hesitate to reach out. We’re here to help you every step of the way on your robotic welding journey!
Where to see cobot welding systems in action
As you explore your robotic welding options, seeing the technology in action can help you make informed decisions. We invite you to experience cobot welding firsthand at the Vention Experience Center (VXC), where you can see a personalized demo tailored to your specific applications and requirements. Our experts will walk you through the entire process, from setup to programming to production-ready welding.
You can also visit us at FABTECH 2025 in Chicago at Booth B15027 in Hall B to see the latest cobot welding solutions alongside live demonstrations. Don’t miss the opportunity to see multiple configurations, ask questions, and discuss how robotic welding can transform your operations.
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Ready to take the next step? Contact us today to schedule your VXC demo or to learn more about meeting us at FABTECH 2025.
