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THG Automation develops CMT twin-wire cobot welding system. The system was built in collaboration with Fronius and Universal Robots. September 22, 2026 By Jared Dodds Sept. 22, 2026, Burlington, Ont. - THG Automation has developed a cobot automated Cold Metal Transfer (CMT) twin-wire welding solution. THG is calling the system, built in collaboration with Fronius and Universal Robots, the first automated system of this kind in North America, installed at a customer facility in August. Targeted primarily for structural engineering and heavy industry fabrication, this system syncs two Fronius TPS/i power sources and wire feeding units to simultaneously feed a twin-drive CMT push-pull torch. The twin-wire cobot welder delivers deposition rates as high as 25kg/h. "We're continually breaking barriers, showing what is possible with a cobot," said THG Automation co-founder and chief executive officer Matt Hendey, in a media release. "With Fronius Twin Wire, customers can achieve submerged arc deposition rates with the ease of use of a cobot with the limitations of a sub arc."

Fronius combines AM, software and automation in new WAAM-based Additive Cell. Published: 9 September 2026 Welding system manufacturer Fronius has introduced its new Wire Arc Additive Manufacturing (WAAM)-based Additive Cell for the production of high-quality metal components. WAAM is becoming increasingly utilised for 3D printed spare parts, prototypes and complex one-of-a-kind components, as modern manufacturing requires ever shorter development cycles, increased material efficiency and complex geometries. Fronius' Additive Cell is engineered to meet these requirements for high-quality metal parts, combining state-of-the-art CMT welding technology, intelligent process control and user-friendly software. In recent years, additive manufacturing has enabled greater customisation, tailored solutions, and spare parts that are available quickly for industries such as automotive, aerospace and oil and gas. Compared to conventional manufacturing processes such as casting, cutting, or milling, additive components keep material consumption and costs low. "WAAM enables decentralised, location-dependent manufacturing without the need for complex production lines," said Manuel Stinglmayr, business development at Fronius International. "Even irregular geometries can be built to the highest quality standards without wasting valuable material." Fronius' additive technology. A stable welding process that enables uniform layer build-up is crucial for achieving the desired quality with the Directed Energy Deposition-Arc (DED-Arc) method. The CMT Additive Pro, which is based on the Cold Metal Transfer (CMT) process developed by Fronius, is particularly well-suited to additive manufacturing as a relatively cool dip transfer arc process that combines a higher deposition rate than other additive manufacturing methods with low heat input. The CMT Additive Pro provides tailored features such as deposition rate stabiliser, Pulsed HotStart, CTWD measurement and power correction to ensure necessary process stability. Stinglmayr added: "The CMT Additive Pro guarantees uniform and, above all, predictable layer build-up across the entire component. This drastically reduces scrap rates as well as the workload required for any rework." The Additive Cell. Fronius' new Additive Cell focuses largely on speed. The coordinated system is designed to meet the needs of various demanding industries. Inside the welding cell, the CMT Additive Pro and Fronius iWave ensure a precise welding process while the Polaris system remains in overall control. "The Additive Cell combines proven welding technology, intelligent control and Fronius' many years of welding expertise," said Anna Dieplinger, key product manager additive manufacuring, automation & digital solutions at Fronius International. "Every component has been designed to complement the other, resulting in a stable manufacturing process." The Additive Cells features the company's proprietary software bundle, Vectris, which brings together the machine tool service kit (MTSK) and post-processor on a single central platform. In addition to an integrated kinematic model, an adapted user interface, and validated welding operations for additive processes, Vectris also supports geometry-based detection of different component regions. This allows for flexible process parameters, such as different settings for outer walls, panels, infills, or component joints. The post-processor is integrated with the FroArc welding command, which translates these build styles into code for the system's welding robot, allowing it to switch to the correct welding parameters at the desired location without delay. The integrated system enables a simple, stable and reliable welding process for metal parts. 360-degree service for AM. Fronius' Additive Cell and its integrated WAAM technology has applications ranging from reverse engineering and optimisation of existing components to entirely new designs. Fronius offers consultation, feasibility studies, process development and production services at its prototyping and manufacturing centre, to assist customers with their requirements. The company can also develop, test and certify the optimal welding and pressure parameters for various welding materials as ready-made, validated 'recipes', which it can license directly to its customers.

Delivering manufacturing agility. Manufacturers are under increasing pressure to expand production capacity, manage labour availability, control costs and respond quickly to changing market demands, all while ensuring uninterrupted operations. As a result, internal logistics is no longer simply a support function. It has become a strategic enabler of productivity, flexibility and long-term growth. For many organisations considering automation, the challenge is not whether to invest, but how to do so with confidence. This was the challenge facing Fronius, a global technology leader in welding systems, photovoltaic inverters and battery-charging solutions. At its production facility in Sattledt, Austria, the business wanted to optimise production supply, improve the efficiency of internal transport and build an operation capable of supporting future growth without sacrificing flexibility. To achieve this, Fronius partnered with KNAPP to implement an intelligent automation solution centred around a fleet of autonomous mobile robots (AMRs). The deployment included 16 Open Shuttle Fork robots for pallet transport and 11 Open Shuttles for load handling, creating a fully connected material flow between goods-in, storage locations and production cells. The result is a streamlined logistics operation that ensures materials are available precisely when and where they are needed, supporting production continuity while reducing manual transport requirements. One of the biggest concerns for manufacturers investing in automation is future adaptability. Traditional automation systems can deliver efficiency but often require significant infrastructure changes and can be difficult to modify as production requirements evolve. Modern manufacturers need solutions that can grow and adapt alongside their business. KNAPP's Open Shuttle technology addresses this challenge by providing a flexible automation platform that requires minimal structural changes and operates safely alongside employees through intelligent navigation, obstacle detection and dynamic route planning. For Fronius, this flexibility was a critical factor in the decision-making process: "We chose KNAPP because their system allows us a very high level of autonomy. The new automation system sets us up for making changes at our location independently, as well as being able to expand our production cells. This makes us faster and more cost-efficient in our overall operation than other systems," said Peter Hubl, Team Leader for Logistics Automation Maintenance, Fronius. This level of operational autonomy enables manufacturers to respond more quickly to changing demand, accommodate production expansion and introduce new processes without the disruption often associated with traditional automation projects. Successful automation depends on more than moving materials from one location to another. Manufacturers need visibility, control and the ability to make operational changes without complex engineering intervention. At the centre of the Fronius solution is KNAPP's KiSoft Fleet Control System (FCS), which provides centralised management of the entire robot fleet. The platform integrates directly with existing systems, coordinates transport orders, manages pallet movements and controls the timely delivery of materials to production areas. Importantly, KiSoft FCS enables Fronius to respond rapidly to production demands while maintaining overall system performance. Real-time dashboards and monitoring tools also provide greater visibility of material flow, helping teams make informed decisions and continuously optimise operations. While technology plays a key role in manufacturing transformation, the long-term success of automation projects ultimately depends on trust, collaboration and ongoing support. Throughout the project, KNAPP worked closely with Fronius teams to design, implement and optimise the solution. Knowledge transfer and employee training formed an important part of the programme, enabling Fronius personnel to take ownership of system management and future developments. Demand for technologies such as photovoltaic inverters, renewable energy infrastructure and advanced power management systems continues to grow as organisations invest in sustainability, energy security and production innovation. As markets evolve, manufacturers must be able to scale efficiently while maintaining the responsiveness needed to meet changing customer expectations. The Fronius project highlights how intelligent automation, advanced software and a trusted partnership approach can help manufacturers achieve exactly that. It demonstrates how the right technology partner can help an organisation reduce operational risk, increase flexibility and build the confidence needed to support long-term growth. For manufacturers looking to future-proof their operations, the greatest value may not come solely from automation itself, but from having a partner capable of delivering certainty in an increasingly uncertain world.