Estes Design and Manufacturing has recently commissioned the latest advancement in its laser welding arsenal to cut production times and costs for customers while providing superior welds. Pairing the shop’s IPG Photonics’ LightWELD laser welding unit with a FANUC CRX-25iA Collaborative Robot (cobot) gives Estes welding production results that are fast, repeatable and precise.
With 1,500 watts of welding power, the unit joins a wide range of materials up to ¼-inch thick without complicated setups and fixturing. The LightWELD can weld any material that can be table, MIG or TIG welded, but because laser welding produces a relatively low heat affected zone compared to MIG and TIG welding, there is a significantly reduced risk of distortion, deformation and burn-through. That quality is particularly important when fabricating thinner materials. Laser welding also performs a variety of weld joint types, including T, butt, corner, lap and edge, and even on dissimilar materials such as copper, stainless steel or aluminum.
The FANUC CRX-25iA cobot takes LightWELD precision to a new level. With a repeatability of ± .05mm, the six-axis cobot provides consistent quality that is essential for cosmetic welds. Robotics also enable the welder to operate at a constant speed every time. Though weld speed is dependent on the machine, manual handheld welding operations proceed more slowly than automated units. Conversely, robotic welders are programmed to advance efficiently from one weld point to the next while human operators need to lift their shields, locate the next weld position then repeat the process.
Estes can use its automated robotic LightWELD cell on virtually all the shop’s operations, including food, medical and even office furniture applications. In addition to its versatility, the unit helps meet workforce challenges as expert welding skills are not needed. Intermediate welders can easily run the machine by simply fixing the parts and starting the cycle. Plus, robotic laser welding is also part of a sustainable manufacturing practice as it produces less scrap and waste.
Laser welding produces welds without filler wire, leaving no weld material build up and requiring little to no grinding as a secondary process. As a result, our customers receive distinctly shorter lead times and reduced production and labor costs.
At Estes, we’re constantly seeking new ways to increase efficiencies with automation and advanced technology for consistent workflow. That translates to faster deliveries and reduced costs for our customers. With conventional, handheld, laser, manual and robotic welding capabilities, Estes has the versatility to provide customers the most efficient and cost-effective production solution for all projects.
Contact Estes today to find out which welding option is right for your next sheet metal fabrication project.
