The total investment goes far beyond the price of the robot itself. A robotic welding cell involves a complete package that covers the industrial robot, mechanical and electrical integration, welding equipment and peripherals, software and programming, staff training, and ongoing maintenance and spare parts. The industry takes this comprehensive approach because it best reflects the true cost over the entire lifecycle of the project.
When considering the industrial robot, this includes the six-axis manipulator, the controller, cables, and servomotors. Each model comes with its own specifications—like payload, reach, repeatability, and compatibility with welding equipment. For refurbished robots, major manufacturers such as KUKA, FANUC, or ABB provide original models, each with defined specifications. It’s important to note that exact prices are not given here, as they depend on the model, year, capacity, and condition.
Mechanical and electrical integration covers mounting the robot on its base or structure, installing the torch and wire feeding system, connecting to the welding power source, and setting up all wiring and safety guards. Much of the real cost comes from adapting the solution to the customer’s specific process, not just the robot itself.
Welding equipment and peripherals vary depending on the process—MIG/MAG or TIG—and may include a compatible welding power source, robotic torch, wire feeder, positioners or rotary tables (if the part requires them), and sensors or tracking systems for applications needing strict tolerances. These components directly influence the quality of the weld.
Software and programming are also part of the investment. This includes initial path programming, process parameter setup, and interfaces between the robot and welding power source. In some cases, offline programming software is also used. Well-structured programming helps reduce cycle times, errors, and rework.
Staff training is considered an essential part of the total investment, as it facilitates daily operation, reduces downtime due to user errors, increases safety, and enables in-house adjustments without always needing outside help. Training can cover basic operation, program changes, safety, and preventive maintenance.
Every industrial system requires preventive maintenance, replacement of consumables, and access to spare parts as needed. For refurbished robots, this point is even more relevant, as the availability of parts depends on the model and its series.
Evaluating return on investment (ROI) involves more than just numbers—it considers factors like reduced scrap, less rework, lower cost per part, increased production per shift, and lower workplace risks. ROI isn’t simply about the price of the robot—it’s about the operational impact. The most important questions are not just “How much does a robot cost?” but rather “What does the complete solution include?”, “How will it affect production, quality, and safety?”, and “What costs will it eliminate or reduce?” Investing in robotics makes sense when the operational savings over time exceed the total system cost.
Interested in learning more or exploring robotic solutions tailored to your needs? Don’t hesitate to contact us—we’re here to help you find the safest and most efficient path forward.