KUKA Advances Modular Construction with Fully Automated Robot Welding System

Starting in 2027, floor and ceiling frames for modular construction will be manufactured using a highly flexible, robot-based welding system. This turnkey system, supplied by KUKA, uses state-of-the-art automation technology to enable nearly fully automated production.

Five KUKA robots weld more than two thousand meters of floor and ceiling frames
The heart of the system consists of five robots that are programmed independently of the product, allowing for customized frame production. The more than 1,000 square meter production area enables efficient manufacturing. Each week, over 2,000 meters of 2D frames are expected to be welded together.

“In addition to increasing efficiency, improving working conditions played a significant role in the decision to automate, aiming to reduce health risks for employees caused by physically demanding postures. Furthermore, new technically oriented job roles are being created,” says Oliver Hartmann, Managing Director of Modular Construction at KLEUSBERG.



Precision and quality: Robots like these weld the floor and ceiling elements together in the system. (Symbolicimage, source: KUKA Group)

Digital and automated – for flexible and efficient production
Thanks to automatic collision checks before production starts and barrier-free data handling with other factory systems, a smooth process is ensured. “Maximum precision is always the focus in robot-based automation. The system can position components exactly and visually inspect the weld seams for quality,” says Andre Zander, Key Account Manager at KUKA Systems Assembly & Test.

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