increasing productivity in manufacturing

White Paper: Increasing Productivity in Manufacturing with New Weld Technology


Heavy-industry manufacturing lines will always need the ability to weld heavy and complex parts well. The ability to weld around the circumference of a heavy part in manufacturing is a complicated process. One of the newest projects we’ve finished this year has revolutionized our client’s welding process, opening up new possibilities for the future of their company and manufacturing process.

The latest free white paper we’ve published features a heavy-industry project that transformed an unreliable and outdated welding system into a safer, more accurate weld cell that doubled our client’s productivity. Our client’s old system had a history of parts slipping during the welding process, despite using 15,000 lbs of force to keep parts in place. 

Any system that produces imperfect parts during the manufacturing process will slow down production and affect a company’s overall throughput. Our client knew they needed a solution that produced accurate welds, kept parts in place during the process, and kept their line operators safe.

Our engineers are experts at designing new processes that overcome any challenges our clients bring us. This project turned into a special opportunity for us to partner with Miller Electric to beta test a brand new welding system that is the first of its kind on the market! Our team also created a unique spring-loaded tool system that solved our client’s particular frustrations with parts slipping with their old system.

Our client needed a process that could hold parts ranging from 50 to 1,500 lbs without slipping or damaging the part itself. Our solution also needed to automatically recognize parts of different sizes and choose the correct steps and tools for each individual part without manual input. The automated solution required a faster welding system that decreased risk of:

  • Porosity
  • Cracking and other quality issues
  • Decreased risk of part slippage
  • Adaptability of the welding process for a variety of complex parts 

Though the goal for this project felt complicated and impossible at times, our engineering team knew they could design a system that met all of our client’s needs, increase productivity, and decrease safety risks for employees and operators close to the process. The result of our engineers’ expertise was an easy-to-use-system that integrated with their other processes to deliver finished products faster than they thought possible.

In this free white paper, you’ll discover how this custom, adaptable system:

  • Saves time and money through reliable tooling
  • Reduces risk of production being stalled because of imperfections in welded parts
  • Saves time through a unique, advanced welding technology from Miller Electric
  • Reduces safety risks to employees through remote operation

To discover more about how Navus engineers used a cutting-edge welding system to design a custom automation process that worked for our client’s needs, you can read all about it in the free white paper, Increasing Productivity in Manufacturing with New Weld Technology.


Navus Automation Inc. is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision and reliability

Not All Integrators Are The Same: How Navus’ Programming Makes Us Stand Out Above Others


We don’t have to tell you about the challenges and complexity of making the different systems in your facility communicate and work together. If you find managing line production day-to-day feels more like a nightmare than the smooth process it should be, you may be partnered with the wrong automation integrator. Choosing the right automation integration partner makes all the difference in how well your systems run, their impact on your day, and the future growth of your company.

No matter what challenge you’re facing in your facility, different automation integrators will always come up with different ways to resolve your challenges. When choosing a partner, it comes down to choosing the smartest solution possible for your company. Integration isn’t just about solving your current challenge, it’s also about looking to the future and seeing possibilities for the success of your business that your current integration partner may not have considered. 

Our team at Navus has proven we stand out above other integrators with our knack for seeing what others didn’t, and applying ingenuity to not only solve immediate complex challenges for our clients, but also to think towards the future and how our turn-key systems can provide intelligent solutions that consider future challenges your company may face. In this blog series we explore how the work that we’ve done sets Navus apart from other integrators.

Additive Manufacturing With Metal Alloy

Additive manufacturing has taken the world by storm in the last several years. While it’s been around since the 1980s, it’s become more of a practical choice for manufacturers as the concept has gotten more advanced, and demand for a manufacturer’s products has increased past the traditional modes of manufacturing. 

A client recently approached us with the need for a robotic gantry that could handle additive manufacturing of 3D metal alloy objects in medium and heavy industry settings. The objects themselves needed to be made with multiple different metal alloys. They essentially needed an industrial 3D printer that could switch between materials seamlessly.

Our client needed a new robotic gantry that could work with one they currently owned. In addition, they needed new, custom software that could anticipate all of their needs and keep both gantries calibrated and working correctly. 

Custom Software for a Robotic Gantry

A robotic gantry without the right software is similar to buying a computer without an operating system. It’s a machine that can accomplish marvelous things, but without the right programming, it’s nothing but an elaborate shell. It was crucial that our client have new custom software to keep both gantries, their current gantry and the one we were building, coordinated. 

Building custom software that integrates existing processes and equipment, which may have been built by a different integrator, and new processes and equipment is a daunting task. The new process merged both gantries together across 13 different axes and kept everything working together within a tolerance of 1mm of welding wire. The intricacy and complexity of what was required of this software was a daunting task. But it wasn’t too daunting for our engineers. 

The end result of this project was a brand new process that combined the old with the new and unique. Our newly built robotic gantry was put on the same track as the one already in place. Our custom software ensured the entire system was calibrated so all 13 axes worked together seamlessly within 1mm of welding wire, and that the robot knew where everything was within a 3D space at all times.

The additive manufacturing process we created could use multiple metal alloys within the same part, allowing our client to create objects with one kind of metal on the inside, and a different one on the outside, or a combination of different metals in different parts of the object. This is something made completely possible through additive manufacturing that could never be achieved through a traditional casting process. 

How Did We Do It?

Our client wanted an addition to their gantry so they could do consistent additive manufacturing with metal alloy in their facility, but they also needed a custom software that kept the robotic gantry our team created working properly.

The biggest challenges we faced were ensuring that axes were coordinated to work together, and blending the real world with the 3D printing world. Both required an enormous amount of calibration and testing.

The system we designed:

  • Gave our client the capability to print 3D parts with metal alloys
  • Kept all of the axes calibrated so they could use the system without fear of it failing 
  • Programmed the robot so it knows where everything is within the 3D space of the gantry
  • Allowed our client to create 3D objects made from multiple types of metal materials

The result? With this new process, our client is able to print objects using metal alloys. If you’re curious how we could help you and your company in a similar way, contact a member of our team today!

Why Are Navus’ Solutions Smarter Than Other Automation Integrators’ Solutions?

It all comes down to our team at Navus. Every one of our engineers is passionate about solving specific challenges for every single one of our clients who partners with us. Our experience, ability to think outside of the box, and passion make all of the difference in ensuring our turn-key system solutions accomplish what other automation integrators can’t. Partnering with Navus isn’t just about figuring out a solution for your current challenges. With every client we partner with, we promise to bring new ideas and solutions to the table that create future possibilities for your manufacturing space, and the future growth of your company. 

Navus Automation, Inc., is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.

For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!

White Paper: Making the Impossible Possible with Sensor-Guided Robotics


Navus has always been known for our ground-breaking welding work, but did you know that we specialize in a range of industry-specific custom automation? Over the years we’ve helped countless clients realize the potential for their business to grow faster and stronger through automated processes. In heavy-industry manufacturing, custom automation can be especially beneficial. 

Feature Project: Custom Robotics Automation Processes in Heavy Industry


One of the things we pride ourselves on at Navus is our ability to help our clients realize the potential for their business to grow faster and stronger through custom automation in their manufacturing facilities. This year we published a feature project that is the perfect example of this.

The Manufacturing Challenge

The client featured in this project handles parts that are multiple tons in their manufacturing facility. The manufacturing process was still manually completed by associates in their facility using heavy and sharp grinding tools. They simply needed a new custom automation process that would minimize manual manipulation from associates, and create faster production times.

The Automated Solution

This new custom automation process:

  • Increased throughput through faster production times
  • Promised consistent quality-assurance
  • Minimized the need for employees to manually complete the process

Discover more about this project!

The finished process gave our client even better results than they had dreamed or asked for. Navus Automation Inc. specializes in making the impossible, possible. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.

Get Started Today!