Ludlow Manufacturing > Case Study

Scaling Robotic Welding Capacity from Two Cells to a Multi-System Operation

Executive Summary

After losing their previous integration partner, Ludlow Manufacturing needed a robotic welding integrator who could not only fill the gap but support sustained growth in cell count and weld complexity. Introduced to United Robotics by Fronius, Ludlow began with two large Ferris wheel systems and custom tooling for a specific customer part. Over the following years, the partnership expanded into a multi-system robotic welding operation supporting new sectors, including data center and transportation. United Robotics delivered the backbone infrastructure — robots, positioners, fume containment, and integration — enabling Ludlow to scale throughput, reduce rework, and position for continued growth.

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Customer Background

Ludlow Manufacturing was formed to service OEM manufacturers with their metal fabrication needs. Since its founding, the company has been devoted to delivering the best products, the highest quality, and the fastest service to its customers — continually updating methods by seeking out the newest technologies and processes. As demand for robotic welding grew within their customer base, Ludlow committed to scaling automated welding capacity rather than relying solely on manual labor.

  • Industry: Contract Metal Fabrication & Welding
  • Location: Waukegan, Illinois
  • Production Environment: Multi-customer, multi-sector robotic welding
  • Growth Sectors: Data center, transportation

The Challenge

Ludlow’s previous integration partner was no longer a viable path forward, leaving an active need for a partner who could both maintain existing operations and scale alongside the business as customer demand grew. The challenges compounded across several dimensions: a need to absorb new customer parts without sacrificing weld consistency, growing complexity in weldments requiring more capable tracking and process control, and the operational risk of standing still in a market where competitors were investing in automation.

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The Solution

United Robotics designed and delivered Ludlow’s robotic welding backbone in stages, matched to the pace of Ludlow’s customer growth. The initial deployment consisted of two large Ferris wheel systems with custom tooling for a specific high-volume customer part. As Ludlow added customers and weldment complexity grew, URI continued to deliver additional cells built around a consistent technology stack:

  • ABB six-axis robotic welding arms across three platforms: IRB 4600, IRB 2600, and IRB 1660
  • Cell positioner configurations: K-1000 kg, 600 kg, and R-300 kg
  • U-2 ABB FlexArc cell for compact, pre-engineered deployment
  • Tracked system with approximately 40-foot center-to-center distance, with positioners capable of elevating and rotating up to 5,000 kg
  • Fronius CMT TPS 500i welding power sources with pulse waveform capabilities for multiple alloys and regulated heat input
  • ABB SmarTac pre-weld tactile joint location and ThruArc real-time through-the-arc seam tracking for process consistency
  • Full fume hood containment across all cells

Ludlow retained ownership of the tooling design and customer part fixturing, with URI delivering the integrated welding infrastructure those tools run on. This division of responsibility kept Ludlow in control of their customer-facing fabrication while leveraging URI’s depth in robotic integration.

  • Dual IRB 4600 Backbone Tooling.jpeg
  • Custom Track System.jpeg
  • IRBP R-300 Backbone Tooling.jpeg

Implementation & Adoption

Each system added to Ludlow’s floor built on the integration patterns established in earlier cells, enabling faster commissioning and shorter ramp-up windows. URI’s approach prioritized communication speed and responsiveness throughout design, install, and post-deployment support — a pattern Ludlow has consistently named as the differentiator versus larger OEM integrators.

"The hands-on training URI brought into our facility was a real difference-maker. Our operators and engineers came out of every install confident in the equipment, and that's what's allowed us to keep scaling our robotic welding business."

  • Todd Ludlow
  • Owner, Ludlow Manufacturing
ABB IRB 4600.jpeg

Results & Measurable Impact

Production Capability:

  • Multiple welding systems added since the initial two-cell deployment
  • Expanded into new sectors: data center and transportation welded components
  • Square footage expansion underway in anticipation of additional robotic welding business

Quality & Process:

  • Improved weld consistency through SmarTac pre-weld joint location and ThruArc in-process seam tracking
  • Reliable, repeatable throughput across an expanding mix of weldments and alloys
  • Custom fume hood containment supporting operator safety across all cells

Partnership Outcomes:

  • Multi-year integration relationship with continued cell additions
  • Active peer referrals from Ludlow to other manufacturers evaluating robotic welding

Customer Feedback

“United Robotics is more nimble with the design, implementation, and support of their cells than the large OEMs. As their customer you’re a partner and not a number. The robotic systems we buy are complex so it’s good to know that URI will take on the challenges put before them and work through all the potential pitfalls and deliver a system you can expect to start up and be in production quickly.”

  • Kevin O’Leary
  • Engineering, Ludlow Manufacturing

“URI wasn’t our only choice for robotic integration, but we’re thrilled with the results they’ve delivered — so much so that we’ve recommended them to several of our friends in the industry when they are investigating their own robotic initiative.”

  • Todd Ludlow
  • Owner, Ludlow Manufacturing

Strategic Impact

With a scaled robotic welding backbone in place, Ludlow is positioned to take on larger orders across higher-growth sectors — including data center components and transportation weldments — without the labor scaling pressure that constrains manual operations. The continuing URI partnership provides a clear path for additional cell deployment as Ludlow’s customer pipeline expands, with established integration patterns that compress time-to-production for each new system.

Call to Action

Looking to scale robotic welding capacity alongside a growing customer base? United Robotics partners with contract fabricators and OEMs to design, install, and support robotic welding systems built to expand with the business. Contact United Robotics to explore how a long-term integration partnership can support your operation.