Automate sanding, deflashing, trimming, drilling, tapping and other secondary operations with robotic systems designed around your parts, process and production requirements.
Sand Deflash Deburr Grind Trim Drill Tap Cut Treat
Built Around the Process
Robot Holds the Tool
Useful for processes such as sanding, grinding, trimming and surface treatment where the tool needs to follow the part.
Built Around the Process
Robot Holds the Part
Useful when a component needs to move through fixed grinders, drills, tapping heads, cutters or multiple process stations.
Real Material Removal Systems
Three Very Different Processes. Three Robotic Approaches.
Robotic Material Removal Application
Robotic Sanding with Force Control
A molded-part manufacturer wanted to automate a labor-intensive sanding process while improving operator safety, dust control and flexibility across multiple parts.
Force / Pressure Sensing Automatic Tool Change Point-of-Source Dust Collection
Removable fixtures supported different parts and job changeovers.
A rotating fixture system exposed the underside for sanding.
The operator could load and unload while the robot continued working.
See the Full Challenge, Solution & Results
The Challenge
Manual orbital sanding created ergonomic concerns and abrasive dust exposure. The system also needed to handle changing part programs and sanding-pad changes without making operation unnecessarily complicated.
The System
A FANUC M-710 robot carried the sanding tool. Pressure sensing helped control tool contact, dust was collected at the source, and a quick-change approach allowed sanding media to be staged without stopping production.
The Result
The robot took over the direct sanding work, the work area was cleaner, and throughput improved because loading, unloading and inspection could happen while another part was being sanded.
Multi-Process Material Removal Cell
Deflashing, Drilling & Tapping in One Cell
This project combined several manual secondary operations into one enclosed robotic system designed to handle a family of twelve molded parts.
12 Part Configurations Less Than 70-Second Target 4 Operators to 1
The robot held the part and presented it to multiple fixed tools.
Grinding, deburring, drilling and tapping happened inside one cell.
Negative-pressure dust control contained abrasive debris.
See the Full Challenge, Solution & Results
The Challenge
Four people were handling sanding, deburring, drilling and tapping across separate manual steps. The glass-filled molded components created dust concerns, the parts were physically difficult to handle, and twelve configurations had to stay within the production cycle.
The System
A FANUC robot carried the part to a high-speed grinder, burr tool, two self-feed drills and an automatic tapping head. Changeable EOAT and HMI recipe selection supported the different part configurations.
The Result
One operator could run the process instead of four, while the enclosed cell improved dust containment, ergonomics, part consistency and throughput. The customer ultimately installed four of the cells.
12 Part configurations
<70 sec Required process cycle
4 → 1 Operators for the process
Surface Treatment Application
Robotic Flame Surface Treatment
An automotive flooring manufacturer needed a repeatable way to prepare molded vinyl flooring so it could meet adhesion requirements without adding floor space or relying on a manual flame process.
The burner was robot-mounted for consistent exposure across the surface.
The inverted design preserved access and the existing equipment footprint.
Automation removed the operator from direct work around the flame.
See the Full Challenge, Solution & Results
The Challenge
The new vinyl flooring program could not consistently pass adhesion specifications. Whatever solution was added had to support the required production cycle, fit the existing area and process three floor sizes.
The System
An inverted FANUC robot carried the flame-treatment burner above the tooling. Programmed paths maintained the target distance, travel speed and exposure time for the different floor sizes while keeping mold access open.
The Result
The manual flame operation became an automated process, improving safety while providing a controlled and repeatable surface-treatment step for the flooring program.
Why Automate It?
Let a Robot do the Work People Do Not Want to Do.
Dust, Noise & ErgonomicsMove operators away from abrasive dust, repetitive motion, awkward parts and demanding finishing tools.
More Consistent ProcessingRepeat tool paths, process position, force, speed and other parameters from part to part.
Keep Production MovingPrevent secondary operations from becoming a bottleneck as volume changes or skilled labor becomes harder to find.
Combine Process StepsWhere it makes sense, one cell can handle material removal, drilling, tapping, inspection and part movement.
Engineering the Application
What Determines the Right Material Removal System?
The robot is only one part of the solution. The complete process has to be designed around the workpiece and the finish or secondary operation you need.
Part Material Plastic, composite, fiberglass, metal and other materials behave differently during cutting and finishing.
Process Force Sanding, grinding and polishing may require controlled contact pressure or compliance.
Tooling Sanders, grinders, burr tools, drills, taps, cutters and treatment tools all drive different cell requirements.
Part Variation Fixture design, EOAT, recipes and changeover strategy matter when one system handles a family of parts.
Dust & Debris Collection may happen at the tool, through cell exhaust or with a fully enclosed process depending on the application.
Cycle Time Process sequencing determines whether one robot performs every operation or multiple steps need to happen in parallel.
Material Removal FAQ
Common Questions About Robotic Material Removal
What material removal processes can be automated with robots?
Common applications include sanding, grinding, deburring, deflashing, trimming, cutting, drilling, reaming and tapping. The exact system depends on the material, part geometry, tooling, required finish and cycle time.
Can a robot maintain consistent sanding or grinding pressure?
Yes. Force sensing, compliant tooling and process control can be used to manage contact between the tool and the part when consistent pressure is important to the application.
Should the robot hold the tool or the part?
Either approach can work. Large or fixed parts often make it practical for the robot to carry the tool. In multi-process cells, the robot may instead carry the part to fixed grinders, drills, tapping heads or other stations.
Can one robotic cell perform several secondary operations?
Yes. When cycle time and part access allow it, a cell can combine processes such as deflashing, deburring, drilling, tapping, inspection and material handling rather than moving the part through several manual stations.
How is dust controlled in robotic material removal?
Dust-control options can include point-of-source collection at the tool, enclosed processing, negative-pressure exhaust and debris collection. The right approach depends on the material and the amount of dust produced.
What makes a manual material removal process a good automation candidate?
Repetitive paths, difficult ergonomics, dust exposure, inconsistent finishing, labor shortages and secondary operations that limit throughput are all good reasons to evaluate robotic material removal.
Have a Manual Process You Want to Automate?
Show us the part and how the work is being done today. We can help determine whether sanding, trimming, deflashing, drilling, tapping or another secondary operation makes sense to automate.
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AUTOMATION
PIONEER INDUSTRIAL SYSTEMS → MOTION CONTROLS ROBOTICS
Pioneer Industrial Systems Support Has Moved to MCRI
Motion Controls Robotics is now handling service and support for existing
Pioneer systems, along with new automation projects.
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