Thick-section structural welding
is not a standard automation problem.
Generic integrators can configure a robot. They cannot design a system around the specific demands of thick-plate MAG welding — distortion control, multi-pass sequencing, heat input management, and inspection requirements. That difference shows up in production, not in the proposal.
Process-First Design
Every system starts with welding process analysis — material spec, joint geometry, distortion tolerance, inspection standard. Robot selection comes after, not before.
Validated Before Delivery
New configurations are proven in AGR's own structural fabrication facility — 50+ robots in daily production — before they reach a client site. Problems stay internal.
Only What We Can Support
AGR does not take projects outside our engineering scope. We are a specialist technical team, not a general contractor. What we commit to, we can deliver and support.
Component
What are you welding? Dimensions, weight, structural geometry. Single part or assembly of multiple components.
Material & Thickness
Base material specification, plate thickness range (6mm–100mm+), joint type, number of passes required.
Welding Requirements
Distortion tolerance, inspection standard (UT/MT/RT), acceptance criteria. Client-specified or industry standard.
Production Volume
Annual output, number of product variants, batch size. Single-model dedicated line or multi-model flexible cell.
Cycle Time
Required takt time per part or assembly. Current manual cycle time as baseline reference where available.
Upstream Conditions
Incoming part consistency — cutting tolerance, fit-up quality. This determines what tracking and compensation the system needs.
Single-station systems.
The right starting point.
A welding cell is a contained, validated unit — robot, positioner, seam tracking, fixtures, and process parameters configured specifically for your component. For most clients new to robotic thick-section welding, this is where reliable automation begins.
Robot + positioner + tracking + fixtures
Each cell is configured around your specific component and weld process. Positioners are manufactured by AGR to the geometry your part requires — not adapted from a catalogue unit.
- FANUC, Panasonic, or ABB robot — selected by application, not preference
- AGR-manufactured positioners: custom axis configuration, load-rated for thick-section components
- Manual, pneumatic, and hydraulic fixture design — engineered in-house to your cycle time and process requirement
- Arc tracking, laser seam tracking, 2D/3D vision — selected by joint type and incoming part variation
- Collaborative robot welding available — fixed workpiece, moving robot, no perimeter fence required where applicable
- Lincoln Electric or Fronius welding source — globally warranted
- Binzel torching — configurable for access constraints
- Fume extraction, safety enclosure, perimeter guarding — integrated as part of the system
- Offline programming capability for multi-variant production
AGR-manufactured positioner. Custom axis configuration per component geometry.
Laser seam tracking. Compensates for joint variation in thick-section fit-up.
Multi-station automation.
When the cell has proven itself.
An integrated line connects welding, handling, and process steps into a coordinated production flow. The engineering complexity multiplies at every station added. AGR builds integrated lines for clients who have already validated the process at cell level and are ready to scale.
Welding + handling + process flow
AGR designs and integrates the welding and robot-related content of production lines. For elements outside our engineering scope, we work with qualified third parties or refer the client directly. We do not take responsibility for what we cannot technically supervise.
- Multi-robot coordination — up to 15+ robots on a single line
- Welding + handling + positioning as an integrated system
- PLC master control with MES connectivity
- Supports 20+ product variants on a single line
- Reference: crane leg bracket line — 15 robots, 8 months to production
- Scope defined precisely — AGR does not over-commit
Multi-robot integrated line in operation. Welding, handling, and positioning coordinated under PLC control.
Moving directly from manual welding to a full automated line without intermediate cell experience has a very high failure rate. The process variables, operator discipline, upstream part consistency, and maintenance capability required for a line are significantly higher than for a single cell.
AGR's standard recommendation is to begin with a validated welding cell, accumulate production experience, resolve the real-world variables specific to your facility and components, and expand from a position of demonstrated capability. A line built on a proven cell process performs. A line built on assumptions does not.
If you already have cell experience and are ready to discuss a line, that conversation is different — and we are ready for it.
Which system fits your situation.
The right system depends on where you are in your automation journey, not just what your production volume is.
Welding Cell
- First robotic welding system for this component type
- 1–3 product variants on a single fixture platform
- Volume justifies automation but not full line investment
- Need to validate process before committing to scale
- Standalone operation, minimal infrastructure change
Integrated Line
- Cell-level process already validated in your facility
- Volume requires continuous flow, not batch operation
- Multiple component types or assembly stages to connect
- Facility and team ready for higher system complexity
- Takt time requirements exceed single-cell capacity
Already have a system?
- Performance issues on thick-section components
- Existing system not meeting weld quality or cycle targets
- Scope and root cause need to be assessed before any commitment
- We will give you an honest technical view of what is achievable
- If a new system is the better path, we will say so directly
Not sure which applies? Describe your component and production situation — we will give you a straightforward technical assessment.
Tell us what you are welding.
Material, thickness, geometry, volume, cycle time requirement. We will assess whether AGR is the right fit and what system configuration applies to your production situation. Direct technical response, no sales intermediary.