State-of-the-art welding technologies for e-mobility: KUKA receives follow-up order from major automotive manufacturer
The newly delivered friction stir welding (FSW) cells—featuring KUKA’s KR FORTEC robots and customized clamping systems—are set to be installed and commissioned in phases by August 2025. These cells will be integrated into electric vehicle (EV) production lines, supporting multiple stages of the manufacturing process.
In the first stage, the robotic systems weld battery cases together. In a subsequent phase, they attach cooling water jackets to the cases. KUKA is managing the complete FSW process, including system assembly, commissioning, operator training, and final handover at the customer’s facility.
Elevating Flexible Manufacturing
These KUKA technologies are being deployed in a thoroughly restructured automotive production plant. The upgraded, flexible facility now supports the assembly of combustion engine vehicles, hybrids, and electric models on shared production lines. A key technical hurdle is the 3D welding of battery trays composed of two cast half-shells—an ideal task for KUKA’s FSW robots.
The factory transformation emphasizes creating a more ergonomic and sustainable work environment while maintaining top-tier quality, efficiency, and customer value.
FSW: High-Performance, Sustainable Joining Technology
Friction stir welding (FSW) employs a rotating pin-like tool guided along the surfaces of the parts being joined. The heat generated by friction softens the material, enabling it to fuse together. This method is especially suitable for joining dissimilar materials, such as aluminum to magnesium, copper, or steel. FSW is more energy-efficient and reduces material waste.
Due to its high seam quality, FSW is widely used in industries with demanding standards, including battery enclosures, high-speed train panels, and rocket tank structures. Beyond EVs, FSW plays a key role in aerospace and electrical sectors.
Robots Built for the Challenge
Robots performing FSW must handle extremely high process forces. KUKA addresses this with its KR FORTEC series MT (machine tooling) variants, equipped with reinforced motors and additional gear stages for enhanced stiffness and performance—ideal for FSW operations.
KUKA is also expanding its offering with two new MT variants from the KR FORTEC ultra family. Featuring a dual swing arm and optimized parameters, these robots deliver 20% greater process force and superior path accuracy. With a reach of up to 3,400 mm, launching in April 2025, they significantly extend the working envelope for FSW applications.
These new FSW robots will be progressively integrated into KUKA’s growing friction stir welding portfolio, including the advanced cell4_FSW modular production cells, new FSW application modules, and customized turnkey solutions designed to meet specific customer needs.
