A flexible platform – compatible with either arc or laser welding – offers job shops an automation platform that can adapt as contract requirements change, reducing the risk of investing in a single-technology system.
For many job shops, the question isn’t whether robotic laser technology welding works – it is whether the business case works. Contract manufacturers often face short program durations, changing part mixes, and uncertain future volumes. A dedicated laser system can be difficult to justify if the next contract requires a different welding process.
IPG Photonics has introduced the FlexCell specifically to address this risk. It gives shops a single automation platform that can support either arc or laser welding. Users can start with the process they need today and then transition as future requirements change. This protects equipment utilization and improves the path to ROI. And, with a price point closer to robotic arc automation than laser systems, it lowers the barrier to adoption
But many manufacturers still view laser welding as more difficult to implement and support than arc welding. Even though robotic laser systems use similar programming methods, users may see the laser process as more specialized and harder to put into production.
FlexCell addresses this need. In terms of day-to-day use, it keeps operators within a workflow that already feels familiar from robotic arc welding, even though the welding process is different. So rather than starting from scratch, users build on skills they already know.
The following provides a practical overview of what it takes to bring automated laser welding into production using the FlexCell.
Starting on Familiar Ground
From installation through daily operation, FlexCell is designed to feel familiar to shops already using automated GMAW systems. Its compact, unitized design simplifies setup, while integrated fume extraction and familiar maintenance requirements help it fit easily into existing production environments.
Operators interact with the system much like they would with a robotic welding cell. The layout, controls, loading process, and production flow are familiar, whether the system uses standard doors or a turntable-style configuration. As a fully enclosed Class 1 laser system, FlexCell is designed to contain laser hazards within the cell, reducing the need for additional external laser safety measures during normal operation.
Programming also follows a familiar approach. Operators still use a teach pendant to jog the robot, teach points, and build weld paths. Coordinated motion and weld sequencing are handled much like robotic arc welding, allowing users to build on skills they already have rather than starting from scratch.
What's Different with Automated Laser Beam Welding?
While the way the robot is programmed stays the same, the welding process is different.
In arc welding, operators control variables like voltage, amperage, and travel speed. Arc welding is usually relatively forgiving, especially when it comes to small variations in joint fit-up or torch position.
Laser welding uses a different set of inputs. It’s controlled through parameters like laser power, travel speed, and focal position. The process is more precise, particularly on thinner materials or parts where distortion needs to be minimized.
So, while the tool has changed, the role of the operator really hasn’t. Their job is still to load parts and run the process consistently using familiar methods, even though the underlying weld parameters are different.
In practice, those parameters are typically developed and validated beforehand. They’re then programmed by engineers into a weld schedule that the operator can call up as needed.
And, when it comes to developing those weld parameters, IPG applications support is available. IPG Photonics can supply FlexCell with process parameters already developed for the specific material and joint. For the system operator, this shifts the focus from trial-and-error testing towards running a consistent, repeatable process.
Small Risk, Big Gains
For shops already working with robotic welding, moving into laser doesn’t have to mean changing everything at once. The equipment, operator workflow, and day-to-day use of the system remain largely consistent with the kinds of automated welding cells many shops already run today.
Getting Started with Robotic Welding
Considering a robotic welding solution? Getting started is easy – view our dual-purpose arc/laser robotic welding systems and talk to a welding automation expert here.
