Why Teo Fabrications Needed a Better Cobot Welding Cell
Teo Fabrications in New Jersey builds race-car chassis and high-mix production parts. They were already renting a robotic cell for welding but ran into three main roadblocks:
- Limited reach for complex joints
- Components that wore out too soon
- Slow, uneven support from the vendor
Shop owner Matt Hearn wanted a more robust package—something that could match a human arm’s flexibility, handle long shifts, and come from a team that answers the phone.
Inside Spartan Robotics' Cobot Welding Cell
Spartan Robotics' cobot welding cell was built around two premium elements:
| Component | Why It Matters |
|---|---|
| Kassow Robots 7-axis cobot | Adds an extra “elbow,” so the torch reaches around fixtures, inside corners, and across large parts without re-clamping. |
| Fronius TPS/i power source | Delivers a stable arc and fast parameter tuning, cutting spatter and rework. |
By combining both, the cell fits in the same footprint as many 6-axis units but can cover more weld positions and paths with consistent torch speed.
Fast Improvement Results on the Shop Floor
Before the cobot welding cell
- Three welders at separate tables handled repeat parts.
- Breaks and fatigue slowed cycle times.
After the cobot welding cell
- One operator loads, starts, and unloads parts; skilled welders move to custom work.
- Overall throughput is 3 × higher than the previous setup.
- Per-employee productivity has doubled on standard parts.
Matt sums it up: “We went from three people on the same job to one person running the robot—and that single station still outpaces our old line.”
Zero-to-Productive in Minutes
Operator Patrick Graham joined Teo Fabrications with no welding or robotics background:
- 20 minutes — time to learn basic operation on a pre-programmed job.
- Simple interface — jog the cobot, set waypoints, save, and run.
While new programs do take planning and validation, Patrick stresses that the workflow is far easier than expected: “It’s user-friendly, and friends keep asking to see videos of what we build with it.”
Welding Support and Service That Sticks
Teo Fabircations gives high marks to Spartan’s service:
- Same-day answers to process questions
- Remote troubleshooting that keeps production moving
- Guidance on best practices for fixtures and torch angles
“The team picks up immediately and gets us back on track,” Matt says. “That keeps our schedules intact.”
Key Takeaways
- Reach equals productivity. A 7-axis cobot covers more joints in one clamp, shrinking idle time.
- Premium components pay off. Pairing Kassow Robots cobot dexterity with Fronius arc stability cuts defects and maintenance.
- Automation reallocates labor. Freed from repeat welds, Teo Fabrication’s skilled welders focus on complex assemblies and process improvements.
- Responsive support matters. Quick answers reduce downtime more than any spec sheet can.
Looking Ahead
With the new cobot cell running at triple the previous output and freeing skilled welders for higher-value work, Teo Fabrications plans to keep refining fixtures and workflows to squeeze even more efficiency from the same footprint. Their experience shows that a well-designed 7-axis cobot can raise throughput and product quality—without expanding floor space or headcount.
How Teo Fabrications Tripled Welding Output with a Cobot Welding Cell