Automated Laser Welding for Ventilation Systems in Ukraine

Client Profile

In 2025, a Ukrainian ventilation component manufacturer sought to improve the efficiency and precision of their welding operations. As a key supplier of HVAC products, they faced growing demand for high-quality, consistent production of complex ventilation parts.

The Challenge

• Complex Component Geometry: Numerous three-dimensional curved welds, internal stiffeners, and variable flange welding positions make it difficult for traditional tooling and manual welding to ensure full-position accessibility and consistency.
• High Quality Requirements: Welds must meet strict standards for sealing, fatigue strength, and appearance. Defects like porosity and distortion are common, especially when welding corrosion-resistant materials (e.g., galvanized steel, stainless steel).
• Production Efficiency Bottleneck: Traditional automation systems require long setup times and lack the flexibility needed for efficient production flow.
• Skill Dependency: It is increasingly difficult to recruit and retain highly skilled welders.

Our Solution

Aixsen developed a highly flexible, vision-guided laser welding cell tailored to tackle the complex welding challenges of ventilation components.

1. FANUC Laser Welding Robot

• Integrated with a line laser seam-finding system to achieve precise part localization and automated path compensation for complex workpieces.

2. Multi-Axis Positioner System

• H-type Single-Axis Positioner: Enables horizontal rotation of the workpiece, optimizing flat and horizontal welding positions.
• U-type Two-Axis Positioner: Supports workpiece flipping and tilting, transforming vertical, overhead, and other complex positions into the robot’s optimal welding posture, achieving full weld coverage.

3. Dedicated Flexible Tooling System

• Modular fixtures designed for the ventilation component family, enabling rapid positioning and clamping.

Implementation

• Offline Programming: Welding path simulation and process debugging are completed before physical production, drastically reducing on-site commissioning time.
• Human-Robot Collaborative Layout: The workstation layout balances automated welding with manual loading/unloading workflows for efficient collaboration.
• Welding Parameter Database: A library of welding procedures for different materials, thicknesses, and joint types enables “one-click calling” to ensure consistent quality.

For high-mix, structurally complex sheet metal welding scenarios, the systematic integration of laser technology + vision guidance + multi-axis positioning enhances both quality and efficiency, building sustainable manufacturing competitiveness for the high-end market.

About Aixsen

At Aixsen, we deliver end-to-end industrial automation systems designed for demanding manufacturing environments.

We deliver precision laser cutting, robotic arc welding, and intelligent material handling solutions—designed as standalone systems or integrated lines, fully engineered around your specific process, quality requirements, and output targets.