Maintenance-free cobots operate in harsh environments

Aircraft Tooling INC

In short

Aircraft Tooling, a Texas-based repair center for the aviation industry, was surprised to find that the UR robots could withstand high temperatures and harsh environments while performing metal powder and plasma spray processes. The cobots have now been in operation for three years without breakdown or service requirements.

The business transformation

Aircraft Tooling Inc. (ATI) was looking into automating repair tasks involving new HVOF (High Velocity Oxygen Fuel) and plasma spray on parts as required within the aviation industry. Juan Puente, thermal spray supervisor with ATI, had initially been recommended to purchase traditional industrial robots but what he found did not meet ATI’s needs.

“The cost was outrageous, the cast iron models we looked at were too bulky, we could not easily move them between cells, they were hard to program, and all required safety guarding, which would not work in our small spray cells,” he says.

Aircraft Tooling INC

Industry Metal and Machining
Country United States
Number of Employees 5-25
Cobots used UR10
Video — UR10 robot, Aircraft Tooling INC., USA

The solution

“The UR10 robot had the required reach for the spray distance and the cost was about half of everything else we looked at. It was very user-friendly and portable. Because of its collaborative safety features, we did not need to fence it in,” explains Puente. He was able to get the UR10 unpacked and programmed in just four hours.

Though Puente readily admits that the UR10 “won their hearts” there was significant hesitation at ATI as to whether the robot would operate reliably in the spray booth’s extremely hot and dusty environment. “We were very surprised. I actually thought the robot wouldn’t stand it. Some of these powder coatings are tungsten carbide which is a hard metal coating. If it seeps into the bearings of the robot, we were afraid it would destroy them,” he explains.

ATI opened up the seals on the UR10 and found the bearings intact. “There were no particles in there, three years of operation, it doesn’t show,” says Puente, adding that recoil from the spray gun was another concern. “We were nervous that the recoil would trip the robot or interfere with the servo capabilities. We went as high as the pressure would take to make it bounce, and it wouldn’t do it. The robot simply stayed in position” recounts Puente.

We were very surprised. We didn't think the robot would stand it.

Juan Puente, Thermal spray supervisor with ATI


Nick Armenta, Automation Engineer with Olympus Controls, the UR robot distributor working with ATI, explains that the company’s experience with the robot’s durability is common: “We very often see the robots operate in harsh environments, taking over jobs that humans don’t want to perform,” he says. “Many think of cobots as being fragile but the opposite is true, this is an extremely durable robot; it’s sealed against dust, rated for high temperatures, and works just as well in extreme environments as in a clean room.”



ATI was also surprised to find that no preventive maintenance is required with the UR robots. “All we do is dust the robot arm off and keep on going,” says Puente, adding that he did not have to pay for a licensing or service agreement. “That was really unusual compared to other solutions we looked at. With the UR robot, everything was included in the purchase price.”



Aircraft Tooling Inc. has grown from a component-only repair station to include overhaul of complete landing gear and engine mount assembly and accessories. The company has continued to maintain exacting standards of quality and workmanship and has become highly regarded throughout the aviation industry. The main objective of ATI’s repair scheme is to restore high-cost parts to new standard dimensions and release for further declared life.

Automation challenges solved:

  • Met industry requirements for automation of spray processes.
  • Achieved production consistency

Key value drivers:

  • Easy programming
  • Collaborative and safe
  • Fast set-up and integration

Tasks solved by collaborative robots

  • HVOF (high velocity oxygen fuel)
  • Plasma spray on parts as required within the aviation industry

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