Fotonix partners with Bochu Shanghai to bring an intelligent robotic MIG welding system to Indonesia. The system, called FSWeld, uses 3D scanning, software, and advanced sensors to enable fully automatic MIG/GMAW welding — without robot programming language. Digital twin technology allows the entire process to be monitored and controlled visually through a computer.
The problem that has held robotic welding back
In real production, tolerances are unavoidable — between the engineering drawing, the fabricated part, and variation from one part to the next. That is not negligence. That is manufacturing reality. In conventional robotic systems, this variation is a serious problem: the programmed path does not change, but the actual workpiece always differs slightly. Reprogramming every time variation occurs is not a solution — too slow, too expensive, and completely unrealistic for production. FSWeld resolves this with a layered approach: scan the whole workpiece, scan each seam, weld, monitor — each stage locking into the next to ensure consistent output regardless of how the workpiece varies.
How FSWeld works
Before welding begins, the BCW181P 3D profiler scans the entire workpiece. The result is matched against the digital model to determine the actual position of the workpiece relative to the robot — no precise fixturing required. The digital twin is updated, and the robot knows exactly where the workpiece is.
From here, the system executes weld seams one by one. Before each seam is welded, the BCW600P laser seam finder scans that individual seam and guides the torch to the exact position with high precision. Only then does the arc start. During welding, voltage monitoring keeps the torch on path — specifically when weaving is used. Once a seam is complete, the BCW600P scans the next one. This continues until the entire job is done.
The entire process — from the initial scan to the final seam — is controlled visually through the CypWeld interface on screen. No robot programming language. No code. No dependence on a robot specialist.
The system performs particularly well on common structural steel profiles — wide flange (WF), H-beam, and channel sections (UNP). Trials we have conducted on these profiles produced consistent welds even where actual dimensions varied between pieces.
Not locked into one function
FSWeld is built around a proven industrial welding robot. When FSWeld is active, the robot operates entirely within the CypWeld environment. When needed, FSWeld can be disengaged and the robot returns to normal manual operation. The robot is not locked to a single function. For facilities that need that flexibility, it is an important consideration.
Integration is part of the system
Fotonix provides FSWeld as a complete integrated system: robot selection, welding cell design, commissioning, and training for your team. We are the one party you need from the start until the system is running on your production floor. Before any purchase decision is made, we run a trial to confirm the system is compatible with your application — because compatibility must be established before commitment. No surprises after deployment.
Who this system is right for
FSWeld is right for anyone who wants to automate welding without needing robot programming expertise. As long as you are welding geometry that can be scanned — structural fabrication, sheet metal, heavy equipment components, or anything else — FSWeld can work. No robot programmer needed. No highly precise fixturing required. Scan, configure, weld. Contact Fotonix to start the conversation — we will begin from the actual condition of your application.
Supported Welding Procedures
FSWeld comes with a range of welding procedure packages built directly into the software — not simple motion programs, but genuine welding intelligence. Available procedures include:
Weaving Welding — supports sine, triangle, L-shape, tilted sine, and pendulum weaving patterns. Pendulum welding is specifically designed for butt joints without grooves on plate thicknesses between 5mm and 16mm.
Wrap Welding — uses laser positioning to accurately detect corner positions and automatically adjust torch posture, producing smooth weld transitions between flat and vertical-up positions.
Continuous Welding — welds multiple seams continuously, preventing stress concentration at intersecting joints and improving overall welding efficiency.
Scallop Welding — as the torch approaches a scallop, the system automatically adjusts torch orientation based on the scallop's shape and dimensions, avoiding collisions while ensuring properly formed weld joints on both sides.
Arc Tracking — automatically compensates for positional deviation in both horizontal and vertical directions during welding, supporting sine, L-shape, and triangle weaving patterns.
Multi-layer Multi-pass Welding — automatically generates multi-layer weld trajectories based on stored parameters including pass offset and torch angle adjustment. Can be combined with arc tracking on the root layer.
Groove Self-adaptive for Box Columns — the system scans the full groove using the laser seam tracker, identifies groove geometry at each laser line, and dynamically adjusts welding speed, current, and weaving width in real time.
All procedures produce welds meeting ISO 5817:2014 Quality Level C and GB 50661-2011 Grade III — measurable, traceable weld quality.
Application Limits
FSWeld is designed for heavy structural steel fabrication with open access — carbon steel and low alloy steel across a wide range of joint configurations. There are applications outside its scope: mirror-finish surfaces, aluminium, circular flanges, and joints that are too short or too narrow are among them. Before you decide whether FSWeld is the right answer — or not — talk to us about your actual application. We will give you an honest assessment.