Figure 1: A comparison of a traditional welding robot in a factory vs a traditional welding cobot being used.
Manufacturers today are facing challenges on two fronts: a shortage of skilled welders and the demand for flexible, cost-effective automation.
Small shops can now consider collaborative robots (cobots) for welding. In the photo above, a compact welding cobot works safely next to a human welder. Cobots are built with sensors and safety features that allow safe human-robot collaboration. They can handle repetitive welding tasks (like tacking and spot welds) all day, freeing up skilled workers for more complex jobs.
Cobots vs. Traditional Welding Robots
When we talk about automation, we mainly look at two players: cobots and traditional robots. Cobots are small, user-friendly robot arms designed to work alongside people. They’re “easy to use, safe, and flexible”. Their force sensors and monitoring software let them stop or slow if a person gets too close. In contrast, traditional industrial robots are built for heavy-duty operations. They excel in speed and payload but operate independently and focus on high-volume production.
Key Factors: Cobots vs. Industrial Robots
Here are some key things to compare when choosing a welding solution:
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- Cost: Cobot welding stations typically start around $30,000–$70,000 depending on if the product comes with a welding setup or not. Traditional robot cells (robot arm + power supply + safety enclosure + installation) often run $50,000–150,000 or more. Cobots tend to have lower price tags and simpler maintenance, while big robots are more expensive to buy, install, and run.
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- Ease of Use: Cobots are designed for ease of use. Many allow hand-guiding (lead-through teaching) or tablet programming. A worker can learn a cobot interface in days or weeks. Traditional robots usually require specialized programmers and months of setup.
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- Safety & Collaboration: Cobots have built-in safety: force and proximity sensors stop the arm if someone enters its workspace. This lets cobots run without fences, right on the shop floor. Industrial robots need guarded cells or light curtains for safety because of their high speed and power.
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- Flexibility: Cobots are portable and reprogrammable, making them ideal for changing jobs. You can move a cobot to a new table or swap its end tool quickly. Industrial robots are typically fixed in one spot with a dedicated task. They can’t be reconfigured on the fly and are best for long, repeatable production runs.
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- Footprint & Integration: Cobots have a compact footprint. They can often sit on a bench or fit inside an existing work cell with little modification. Traditional robot cells need extra floor space for fences and often require changes to the facility. Cobots like SwitchWeld are often “plug-and-play” and integrate into your workflow with minimal hassle.
Which is Right for You?
Cobots are especially attractive for high-mix, low-volume shops. They let you automate diverse welding tasks on demand and fit in tight spaces, enabling small shops to take on jobs they might otherwise turn down.
However, traditional industrial robots still excel in very large production runs and heavy-duty welding. If you weld thick structural parts in long runs, a powerful industrial robot can far outproduce any cobot. These robots deliver the highest speed, payload, and consistency for large volumes, though they need more space and safety measures.
The choice depends on your shop’s needs. For many small shops new to automation, cobots offer a friendly, cost-effective start. IFR notes cobots are growing quickly (about 10.5% of new robot installations in 2023) and were designed for companies without big engineering teams or large batches. You can often program a cobot by hand or tablet with no code, so workers can get up to speed without much outside help.
Many manufacturers find a hybrid approach works well: use cobots for flexible, short-run jobs, and add an industrial robot for heavy welding later. Either way, automation can boost your throughput and weld consistency, freeing your team from tedious tasks. Cobots make automation more accessible than ever. Now you have the information to pick the solution that fits your shop and helps your business grow. If you have any questions, contact us and let us know.