The Future of Welding Automation: nexAir’s Role in Supporting the Evolving Industry

Manufacturers are under growing pressure to increase output, reduce rework, and fill skills gaps. Welding automation has become a key part of how shops adapt—offering more consistent welds, longer runtime, and better use of available labor.

But automation isn’t just about adding a robot. It changes how everything else operates. From gas flow to operator responsibilities, each system has to be adjusted for the demands of automated work.

nexAir supports customers through that shift by helping them manage the parts of the process that don’t always get attention: how gas is delivered, how teams are trained, and how the system holds up as production increases.

Optimizing Gas Systems for Automation Success

Automated welding creates distinct gas delivery requirements compared to manual operations. Robots typically maintain longer duty cycles, require more precise shielding consistency, and perform multiple welds without interruption.

We collaborate with manufacturers to design gas systems engineered specifically for these demands. This includes selecting automation-grade regulators with faster response times, optimizing distribution pathways to eliminate pressure fluctuations, and implementing monitoring systems that detect variations before they affect production.

For high-volume operations, we often recommend transitioning from individual cylinders to microbulk delivery systems. This change eliminates disruptive cylinder changeovers, maintains more consistent pressure, and reduces handling risks – all crucial factors in maintaining continuous automated production.

Developing Team Capabilities for New Technologies

Automated welding changes how gas is used. Robots run longer duty cycles, require steady shielding, and don’t pause between welds. These conditions make consistent flow and pressure more important than ever.

nexAir helps design gas systems built for this level of demand. That includes selecting regulators suited for automation timing, adjusting line routing to reduce pressure drops, and, where needed, transitioning from cylinders to microbulk. These changes help eliminate mid-shift interruptions and reduce handling risks—two factors that directly affect production stability.

We focus on giving the gas system the same reliability expectations as the robot itself.

Creating Infrastructure That Grows With Production

Most automation journeys begin with a single robotic cell before expanding. As manufacturers add stations or increase production volumes, gas systems designed for smaller operations often become limiting factors.

We help teams prepare for growth by analyzing current gas consumption patterns and projecting future requirements. This forward-looking assessment identifies potential bottlenecks before they impact production and determines whether existing infrastructure can support planned expansion.

Our expert KnowHow™ allows us to recommend practical solutions based on experience across hundreds of automation implementations. We apply these insights to help manufacturers optimize their current systems while preparing for future growth.

Preparing for Tomorrow’s Manufacturing Environment

The welding industry continues evolving toward greater automation, increased process sophistication, and higher reliability standards. nexAir helps manufacturers Forge Forward by ensuring their foundational systems – gas delivery, workforce capabilities, and infrastructure design – develop in parallel with their automation technology.

This comprehensive approach creates production environments where advanced equipment performs to its full potential, supported by optimized delivery systems and knowledgeable teams ready to meet tomorrow’s manufacturing challenges.

Contact us to learn more about preparing your welding operation for automation success.