It all started with a spark – literally. In 2015, a team of engineers in Tennessee set out to make cobot welding accessible and American-made. Robotic Technologies of Tennessee (RTT), a start-up from Tennessee Tech University, joined forces with AUBO to build a portable, mobile welding cobot from scratch. Using RTT’s own welding process controls and motion-planning software together with AUBO’s high-quality robot arm, the team quickly proved the concept in demanding shop-floor conditions. By 2016, SwitchWeld systems were hard at work in the toughest applications – Navy shipbuilding, power-plant fabrications, and civil structures – running continuous welds and putting the technology through its paces.
RTT then partnered with the Edison Welding Institute (EWI) to refine the welding algorithms and quality controls, ensuring the cobot met the most stringent weld codes. Every detail was optimized in Tennessee – from the weld program software to the intuitive user interface – with the goal of simplifying automation for any welding shop. Their prototype made a splash at FABTECH 2018: an orange CRWeld cobot was the only robotic welder on display, drawing crowds. Engineers on the show floor demonstrated the system’s revolutionary “pendant‑free” teaching method – welders could guide the torch by hand and fine-tune the seam path using a 6‑DOF joystick, all without stepping away from the workpiece. In short, the SwitchWeld team had done the unthinkable: they made industrial robotic welding as intuitive as swinging a torch by hand.
Pioneering Performance: From Navy Shipyards to Fabtech Fame
Armed with this new cobot, SwitchWeld proved its quality immediately. By 2016, pilot systems were embedded in live Navy shipbuilding and heavy fabrication projects, outperforming traditional methods even under the most grueling conditions. RTT’s engineers worked hand-in-glove with welders to meet Naval and power-industry specs – a collaboration that ultimately delivered a machine so reliable it “was the only welding cobot operating on the FABTECH floor” in 2018. That debut launch – essentially a one‑off cobot at a huge show – demonstrated how SwitchWeld was ahead of its time.
From the outset, SwitchWeld embraced American design and craftsmanship. In 2025, the system earned official “Made in Tennessee” certification, highlighting its “unwavering dedication to American design and manufacturing”. As SwitchWeld’s team often points out, every line of code, every element of the UI, and every chassis and cart design was developed at their Tennessee headquarters. This isn’t imported hardware with a U.S. sticker – it’s a truly domestic solution engineered by welders and engineers in the heart of Tennessee.
Intuitive Welding Interface: Joystick‑Guided, Pendant‑Free
What really sets SwitchWeld apart is its user interface. From Day One the goal was to eliminate the programming headaches that repel many welders from automation. Instead of a cryptic teach pendant or offline coding, SwitchWeld lets a welder teach a weld path by hand and then fine-tune it on the spot. In practice, an operator simply holds the welding torch (mounted on the cobot arm) and sets wayppoints along the seam. The system records those points, then the welder can edit any points to smooth out any bumps or adjust the path – all at the torch, not at a distant console.
This idea for a pendant‑free workflow was revolutionary. As SwitchWeld’s founders explain, “the offer was ‘pendant-free’ weld teaching. The welder could do the majority of the weld teaching right at the torch.” Complex weld geometries – like pitch changes or weave patterns – become simple to program by hand, while the software’s advanced path‑blending algorithms ensure a smooth, high-quality result. In short: no coding, no offline programming, no intermediaries.
But after testing, the SwitchWeld team quickly learned that the detriments of pendant-free quickly outweighed the benefits. With no pendant, modifying programs was incredibly difficult, making small fixes in position a big hassle. Implementing complex functions like copy and paste became much more simple with a teach pendant, and other pieces of hardware – like the 7-th axis of the SwitchWeld Reach and the plasma cutting attachment – became possible with the use of a pendant.
SwitchWeld went through extensive testing, which allows the final product to be specialized for ease and efficiency. In the end, SwitchWeld UI is built specifically for welders.
See it in action: A SwitchWeld system (with optional 7th-axis turntable) in a job-shop. This American-built cobot welder lets operators teach welds by guiding the torch and fine-tuning with a joystick, right at the part. (Put video of SW Reach Here)
Why SwitchWeld? Key Advantages
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- Plug-and-play welding automation: No robotics expertise required. Welders teach by hand and use the intuitive interface; no complex programming or integrator needed. The system was hand-crafted by our own engineers, and the software behind the movement was made in house, something special to SwitchWeld.
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- Six-DOF fine‑tuning: A 6‑axis joystick on the torch allows welders to smooth and perfect the seam path with fingertip precision. Unlike other cobot welders, users do not need to use the jog page to precisely move the arm. The cobot can be moved using the specialty joystick on the end of the arm, built in house by SwitchWeld’s dedicated engineers.
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- High-quality AUBO cobot arms: SwitchWeld uses AUBO Robotics collaborative arms – globally respected, open‑architecture robots originally founded in Tennessee. These arms are tested and built for reliability.
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- Advanced motion planning in-house: Proprietary software (developed in TN) blends the taught path and applies optimal welding parameters (via ArcAdvisor™), ensuring consistent, code‑quality welds.
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- Compact, Mobile Design: The entire system is on wheels and compatible with common MIG welders or plasma cutters. It can be moved between booths or jobsites, making automation flexible for any shop layout. The SwitchWeld Basic can be attached to any preexisting table and SwitchWeld Reach can be used to extend the workspace. SwitchWeld can be implemented into any shop, for any shop’s needs.
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- Rapid ROI: Customers regularly report dramatic productivity gains. In one plant, a part that used to take 20 minutes per piece now runs six parts in the same time – with perfect consistency. With the SwitchWeld system costing approximately 20% less than other companies, the ROI is even higher. Shop owners can make back their investment quickly with SwitchWeld.
These benefits come wrapped in quality. SwitchWeld’s design center is in Cookeville, TN, where U.S.-trained engineers craft the hardware and user interface. The result is an American-made welding automation package – software, electronics, and mechanics – all built under one roof.
From the Shop Floor: What Welders Are Saying
Don’t just take our word for it. Real switch weld owners and operators have seen the difference firsthand:
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- “Before the SwitchWeld unit, we were welding one of these parts every 20 minutes. Now, we are doing 6 parts in 20 minutes with high quality and amazing consistency.” – Production Engineer, Machine Building.
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- “The joystick is really a game changer… The welders are able to fine-tune the welds with the intuitive joystick on the end. With the SwitchWeld, three people’s jobs were done by this one machine… Minimal training is needed and very easy to use.” – Plant Manager, Metal Fabrication.
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- “SwitchWeld has made welding and plasma cutting sexy again. Our team absolutely loves working with this technology, and it’s become a huge part of how we retain top talent.” – Fencing Shop Owner.
These testimonials highlight the core promise: SwitchWeld revolutionizes workflow without fear. Welders immediately appreciate the hands-on simplicity, and managers see throughput and quality soar. (Want to see it for yourself? Schedule a free demo with our team and put it to the test!)
The AUBO Edge: Precision by Design
A big part of SwitchWeld’s performance comes from its arms – made by AUBO Robotics USA. AUBO started in Tennessee (founded at UT in 2010) and today is a global leader in cobots. Their location in Detroit, MI supports SwitchWeld’s R&D, while precision robot arms are built in AUBO’s advanced factory. Importantly, AUBO controls the entire production line, from components to final assembly.
Vertical Integration for Quality: “Our vertically integrated manufacturing process… allow[s] us to control even the slightest inconsistencies to ensure the pinnacle of durability, lifespan, and design” states aubo-usa.com.
That means every AUBO arm is assembled and tested with meticulous care. Before any SwitchWeld is shipped, its arm has been pushed through 160+ rigorous tests – everything from vibration and heat-soak to precision repeatability – so shops know the robot will keep welding part after part without failure. Thanks to this process, AUBO even saw its supply chain withstand recent global disruptions and kept parts flowing to American customers.
By partnering with AUBO’s Tennessee-based arm technology, SwitchWeld combines “engineer-level support, no middlemen” (just as our home page promises) with the peace-of-mind that comes from certified, American-quality equipment.
Looking Ahead: Quality, ROI, and American Manufacturing
Today, SwitchWeld stands poised on a new frontier of fabrication. It’s not just another welding robot – it’s a symbol of reshoring high-tech manufacturing and investing in our own workforce. By building these systems in Tennessee, SwitchWeld ensures fast support (no overseas support) and re-invests in local jobs. Welders will get trained by a SwitchWeld application engineer, no middleman needed.
Financially, the advantages are clear. With a SwitchWeld cobot, shops routinely multiply output while cutting costs. One system has increased producation for three welders at once; another reports 10× efficiency gains in fabrication. That means a quick return on investment – often in just a few months – turning automation from a gamble into a smart, cost-saving decision. And because SwitchWeld is modular, shops can start small (even under $40K) and scale up to full multi-axis cells as needed.
At the end of the day, SwitchWeld’s story is far from over. Our Tennessee team continues to refine the technology – adding plasma cutting capability, integrated weld sensing, and making the interface even more intuitive. One thing won’t change: our promise to deliver the highest quality American-made welding automation with world-class support. As one testimonial put it, “This investment is not just about boosting productivity; it’s about empowering our team to push the boundaries of what’s possible and continue delivering top-notch quality” – forging a brighter, more innovative future for U.S. manufacturing.
Ready to revolutionize your welding shop? Discover the difference a SwitchWeld can make. Request a free demo or contact us today and see firsthand how this cobot welding system combines intuitive simplicity, robust Tennessee engineering, and rapid ROI to supercharge your production.
