Gone are the days of relying solely on manual skills and traditional techniques in the metalworking industry. We're entering a new era of manufacturing powered by automation, precision technology, and adaptive intelligence.
Your competitors are no longer the shop down the street but advanced facilities leveraging robots, artificial intelligence (AI), and interconnected systems that can produce higher-quality parts faster and more consistently than ever before.
So, what’s a factory to do? Keep reading to find out!
Here’s what we’ll cover:
- Key challenges in metalworking
- Automating different metalworking processes
- Top automation solutions to consider
- Impacts on other industries
- Future of automation in metalworking
CHALLENGES DRIVING AUTOMATION IN METALWORKING
Shrinking skilled labor pools, increasingly complex customer demands, and never-ending global competition. Metalworking companies face growing challenges — but there is help!
Labor shortages
It’s no secret that the industry is experiencing a serious skills gap. Experienced machinists and welders are retiring, and fewer young professionals are filling those shoes. Solutions like collaborative robotic applications (cobots) are helping to bridge this gap and keep operations running. Take Thyssenkrupp Bilstein, a leading supplier of high-tech components for the auto industry, who employed cobots to lend a hand — or a few — to overcome staffing shortages.
Demand for precision and quality
In industries like aerospace, medical devices, and automotive, there’s no margin for error. Even the slightest inconsistencies or deviations can lead to product failure or increased costs due to rework and waste. However, ??automation can help reduce variability and keep a close eye on quality with AI and vision technology.
Global competition
International and emerging markets are becoming technological powerhouses that can produce high-quality components at unprecedented speeds. For traditional shops, the message is clear: robotics has become the great equalizer. They allow small to medium-sized manufacturers to compete globally by implementing automation technologies that augment human capabilities, delivering precision, efficiency, and competitive pricing.
Material costs and sustainability
With raw material costs skyrocketing and environmental regulations getting stricter, manufacturers are turning to IIoT-enabled sensors and intelligent automation technologies. With them, they can track material usage in real-time, optimize cutting and forming processes, reduce waste through precise material management, and monitor energy consumption across production lines.
Complex design requirements
Gone are the days of one-size-fits-all manufacturing. Today's customers demand highly specialized, custom-designed components delivered with unprecedented speed. This shift towards just-in-time manufacturing requires unprecedented agility. Enter Multi-axis CNC (Computer Numerical Control) machines and robotic systems. They can quickly adjust to design changes, handle intricate details, maintain consistency, and even integrate complex design modifications.
HOW AUTOMATION HELPS METALWORKING PROCESSES
With greater precision, efficiency, and speed, automation is helping meet rising demands and navigate industry challenges. Let’s examine how it helps at process levels.
Automation for casting
Traditional casting often results in wasted material or imprecise shapes that need finishing. Automated casting systems pour molten metal at the right temperature and pressure to reduce waste and improve the quality of the cast.
At the same time, these systems can control the cooling rate, which is critical to achieving the desired metal properties like strength or hardness. Plus, automation can help streamline operations by managing multiple molds simultaneously, significantly improving throughput.
Automation for forging
In the past, forging required significant human effort, with workers manually controlling the machines to apply pressure. Today, automated forging presses and hammers have taken over, offering precise control over the force applied to the material.
Automation also speeds up the forging process, meaning manufacturers can produce larger parts without sacrificing quality. In industries like automotive and aerospace, where parts need to meet high standards of strength and precision, automation is key to reducing defects and ensuring product performance.
Automation for machining
When it comes to machining, whether you're working with CNC machines or automated lathes, automation takes precision to new heights. In the past, manual machining required a lot of skill and time. For example, an operator had to manually adjust the machine settings, make measurements, and ensure everything was perfectly aligned.
Today, CNC machines, powered by automation, do all that with just a few simple inputs from the operator. These machines can create highly detailed components, from intricate automotive engine parts to aerospace components, at incredibly high speeds and with exceptional accuracy.
Not only does automation increase productivity, but it also reduces human error, meaning fewer defects and rework. With machine learning, some CNC systems are even becoming smarter and can adjust settings in real time based on environmental factors like tool wear or material inconsistencies, ensuring consistent quality on every run.
Automation for cutting
Cutting metal can be a challenging process, especially when precision is required. Traditional cutting methods often involve manual adjustments, which could lead to consistency or excessive material waste. Automated laser, plasma, and water jet cutting systems are changing the game. These systems offer precise cuts that minimize waste and maximize the use of raw materials.
Laser cutting, in particular, offers high precision and can easily handle complex shapes. Plasma and water jet cutting systems can also cut through thick metal plates or other materials with high efficiency, making them perfect for industries that need robust, reliable cuts like construction or energy.
Automation for welding
While traditional welding requires skilled operators to weld parts together by hand, robotic welding systems now perform these tasks with impeccable precision and speed. They can help ensure that each weld is consistent, clean, and reliable. They also can work continuously without breaks, boosting productivity and reducing costs.
Robotic welding is particularly beneficial in industries like automotive manufacturing, where high-volume, high-quality welding spans everything from exhaust systems to car body frames. Additionally, robots reduce the risk of worker injury.
TOP INDUSTRIAL AUTOMATION TECHNOLOGIES FOR METALWORKING
Staying ahead of the curve is crucial in metalworking — and automation makes it possible. From CNC machines to robotics, let’s look at automation solutions reshaping metalworking.
CNC technology
If you’re in metalworking, you’ve likely encountered CNC machines. These machines take over tasks that require incredible precision, like machining engine components or intricate parts for aerospace. Thanks to automation, modern CNC machines are faster, more precise, and can work around the clock. Plus, they’re adaptable. You can program them for different parts and easily switch between jobs without missing a beat.
Robots
Whether it’s robotic arms handling welding or assembly or cobots working side-by-side with humans, automation is bringing precision, speed, and flexibility to the factory floor. Cobots, in particular, are designed to work safely alongside workers, performing repetitive tasks like lifting, placing, or handling parts. This frees up human operators to focus on more complex or higher-level work.
AI and machine learning
By analyzing historical data and patterns, AI can predict when a machine might fail or how to optimize production runs for maximum efficiency. On top of that, machine learning algorithms improve over time, getting smarter and more accurate the more data they process. This can lead to fewer mistakes, less waste, and smoother operations overall. And since AI is always learning, your systems are constantly getting better without any extra effort on your part.
IIoT and smart sensors
Smart sensors and connected devices provide real-time data, giving you insights into everything from machine performance to material usage. With IIoT (Industrial Internet of Things), companies can monitor processes continuously, minimizing downtime and making more informed decisions about maintenance, inventory, and workflow.
Digital twins
This technology is making waves across a few industries. A digital twin is a virtual replica of your factory or machinery that mirrors real-time data from the physical world. By simulating production processes digitally, companies can test different setups, predict maintenance needs, and avoid costly mistakes before making a physical change.
GOING BEYOND THE SHOP FLOOR
Metalworking might seem like an industry that operates behind the scenes, but its influence stretches across various other sectors. Let’s take a quick look at how advancements in metalworking can have a ripple effect on the progress of other industries.
Driving innovation for automotive
From finely machined engine blocks to lightweight structural components, the precision and durability demanded by the automotive world depend on advanced metalworking techniques. With automation, factories are meeting these exacting standards faster and more cost-effectively — helping to drive the shift to electric vehicles and beyond.
Reaching new heights for aerospace
In aerospace, there’s zero room for error. Aircraft parts must be strong enough to endure extreme forces yet light enough to support fuel efficiency. Thanks to innovations in machining, forging, and casting, metalworking delivers components that keep planes in the air and passengers safe. Automation takes it a step further, enabling the production of intricate, high-tolerance parts that are critical for modern jet engines and fuselages.
Powering up for energy
Whether it’s a wind turbine towering over a field or a pipeline carrying vital resources, metalworking makes it all possible. The energy sector relies on metalworking to create everything from turbine blades to intricate pipeline components. Automation has become essential here, boosting efficiency in the production of renewable energy structures like solar panel frames and wind turbine housings — paving the way for a greener future.
Fortifying the foundation for construction
Skyscrapers, bridges, and stadiums all start with a foundation of expertly crafted steel and metal components. Metalworking provides the beams, fasteners, and other structural pieces that make these architectural marvels a reality. With automated cutting and welding, construction firms are getting these essential materials faster and with pinpoint accuracy, ensuring that every piece fits together like a giant puzzle.
Upgrading for electronics
Your smartphone, laptop, or gaming console — they wouldn’t exist without metalworking. This industry produces the intricate metal enclosures, connectors, and conductive components that make electronics possible. As devices become smaller and more complex, automation ensures that these delicate parts are manufactured with the precision needed to meet skyrocketing demand.
WHAT’S NEXT FOR METALWORKING AND AUTOMATION
Metalworking isn’t just about shaping; it’s about shaping the world. As we look to the future, we anticipate a move towards "lights-out manufacturing," where factories can operate 24/7 with minimal human intervention. But here's the crucial part: this doesn't mean replacing workers. It means upskilling them.
Companies are investing in training programs that help operators work with automated systems, not against them. This way, employees can feel confident, supported, and empowered to navigate the future.
In addition, sustainability will continue to become a powerful motivator. Automated factories consume about 20% less energy on average. So by embracing automation, you’re not just becoming more efficient, you’re becoming more environmentally responsible — a bonus with younger generations.
TAKE YOUR NEXT STEPS AT AUTOMATE
The automation revolution in metalworking isn't coming — it's already here. The question is: are you ready for it?
Check out the latest automation technologies, connect with industry leaders, and talk shop with others in metalworking and manufacturing. It’s all waiting for you at Automate, the largest automation trade show in the Americas. The best part is it’s FREE to register!
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