Among its many features, the MODO Robot system also includes the ROBO-TOOL wizard, which allows users to design their own robotic grippers and integrate them into the machine.

For companies with extensive product catalogs and frequent new product launches—or, even more so, for contract manufacturers that continuously handle components that vary in geometry, material, and lot size—one of the main challenges of robotic automation is integrating the new object-gripping tool into the machine.

Therefore, if every new item requires external processing, automation remains limited to high-volume SKUs; otherwise, long lead times and high costs would make small orders uneconomical.

ROBO-TOOL eliminates all of these issues, as the user can independently design the gripper needed to handle the new part and create new machine recipes safely, easily, and with step-by-step guidance.

In fact, it allows you to:

• define the tool (gripper) in the machine’s software;
• enter its physical limits, that is, define its maximum range of motion;
• assign multiple base work planes to the tool.

Consequently, the introduction of new items can be managed directly by the production department.

ROBO-TOOL thus transforms automation from a one-off, supplier-dependent project into a flexible, frequently used tool that is fully managed by the user.

The main advantages are:

• Machines are always aligned with the product catalog.
• Shorter lead times for introducing new items.
• Quick, safe, and repeatable format changes.
• Better return on investment, thanks to more extensive use of the machine.

When it comes to concentrically welding cylindrical steel objects in high-tech applications—such as special valve bodies, manifold blocks for pressurized fluids, and nozzles (in the chemical, energy, food, biotechnology, automotive, research, etc.), the MODO Weld laser welding system—featuring a 2 kW torch and a spindle—can be the key to success.

The MODO Weld system offers:

• Spacious work area for equipment, fixtures, gas injection nozzles, and fume extraction
• full automation of the welding process
• Maximum safety for the operator
• Great flexibility for processing parts of various shapes and sizes
• Setting up and configuring the machine does not require personnel with programming expertise (no lines of code to write!).

Let’s consider the example of automatic laser welding of two concentric cylinders made of AISI 316L (2 mm thick): the components, which have already been spot-welded or clamped in place with a fixture, are secured to a mandrel tilted at a 20° angle to optimize laser alignment. To ensure the highest quality, the welding zone is completely inerted by blowing argon gas both inside and outside the cylinders; by utilizing the Z-axis movement of the laser head and activating a pneumatic accessory, the diffuser nozzles automatically move toward the welding zone.

The programming steps can be summarized as follows:

• Teaching Program.The project is defined using an intuitive console; a sequence of machine operations (Planned Program) is organized along with the corresponding parameters.

• Validate & Simulate. Press the corresponding button to validate the program you just entered, allowing the software to automatically generate the G-code. With the laser turned off, you can simulate all axis movements using the joystick.

• Create Production Project. Insert the Teaching Program you just saved into the CNC Program.
• Program Execution. Loadthe project and start machining by pressing the physical button.

At this point, the machining chamber door closes automatically, and the operator can monitor the machining process in complete safety through a Virtual Window (a “virtual window” in which the work area is viewed by a camera from the same vantage point as the “window” itself).

The result is a uniform, full-penetration weld even when using less than half of the available power, as demonstrated by the tests conducted in our metallographic laboratory.

Weld Bead	% Max Power	Welding cross-section
	45%
	55%
	60%

The MODO Weld system is the result of Sisma’s 25 years of experience in laser welding.

From the feasibility study through to after-sales service, Sisma supports the customer to ensure they quickly achieve complete autonomy in taking full advantage of the machine’s great versatility.

Key advantages of the MODO system:

• Operational autonomy: A single operator manages the entire work cycle independently and quickly.
• Guaranteed quality: maximum repeatability and waste reduced to a minimum. Once the parameters are set, the margin of error is close to zero.
• Gas efficiency: MODO’s software optimizes the flow of shielding gas, directing it only where and when it’s needed, eliminating all waste.

Traceability: The Starting Point

Every prosthesis and every medical device must be uniquely identifiable throughout its entire lifecycle. It was this need that led Sofab Orthopédie, a major holding company based in the Rhône-Alpes region, to reach out to Sisma: to laser-mark prostheses and other metal medical devices while maintaining the high quality and meeting the stringent requirements of the medical field, all while streamlining production.

Marking is the foundation of UDI (Unique Device Identification) traceability [Learn More], as required by FDA regulations and the EU MDR.

The customer’s goal was clear: a stable marking process on a reliable machine, with a high degree of automation and flexibility. The system operates 5 days a week, in two 8-hour shifts.

The Challenge: Different Parts, Same Standards

Versatility. The project involves five very different product families: femoral heads, tibial stems, double-mobility cups of various sizes, other prostheses, and surgical guides. A single machine must handle parts with different geometries, dimensions, and implant positions.

Repeatability and precision. The customer requires medical-grade blackening marking: chemical resistance and excellent legibility on cobalt-chromium, titanium, and stainless steel. All of this must be achieved with very short cycle times to increase productivity.

Integration. The system must communicate with the company database via SQL queries, automatically load marking projects, and automatically detect the position of components.

The Sisma Solution: BSP Pico with WH10 Vertical Magazine

To meet these needs, we proposed the BSP Pico laser marker combined with the WH10 automatic loading magazine featuring 10 trays. The magazine increases productivity and the level of automation, and enables unattended operation. The software is integrated with the customer’s SQL database: it retrieves data, generates the UDI marking, and automatically loads the marking projects.

Materials and Finishes: Testing Readability

In consultation with the customer, we tested four materials, developing two sets of parameters for each, in search of the best quality in the shortest possible cycle time.

The benchmark. The sample is a partially polished metal disc. We marked two 2D codes on both the polished and the matte sides for each set of parameters. The result is four different levels of readability, to verify how the finish and parameters affect reading.

Accuracy, repeatability, and part recognition: CVS and Pattern Matching

Dimensional accuracy. On the X2CrNiMo steel samples, we measured the letter “Q” and the tail of the arrow. The measured values are 1.9916 mm and 1.5713 mm, compared to expected heights of 2 mm and 1.5 mm.

Measured repeatability.

To simulate mass production, we marked a series of elements (0.5 × 18 mm rectangles) on the plane in the X and Y directions, with a pitch of 10 mm. The positions were defined using the Coaxial Vision System (CVS)

[Learn more]. The marking was then repeated using the MULTI software option, setting the offset on the axes.

The maximum deviation from the nominal position was 15.5 µm over a 90 mm stroke.

Part Recognition. The combination of CVS and Pattern Matching [Learn More] ensures the precision and reliability required for mass production by automatically recognizing the part and detecting its position.

Durability: The marking remains intact; the material does not deteriorate

A medical marking must last as long as the device itself, without compromising the material. That is why we subjected it to two tests under particularly harsh conditions.

We have carried out:

• Boiling test ( Test G of ASTM A967/A967M-17), in which no sample developed rust: the laser did not compromise the surface’s passive layer.
• Sterilization test. The customer conducted an additional autoclave test on 24 samples to simulate wear from normal use. After several cycles, all markings remained easily legible, and no sample showed signs of rust.

Conclusions

The collaboration between Sisma and Sofab was essential to achieving a repeatable process that complies with medical regulations.

The Design Qualification (DQ) defined the acceptance criteria and the necessary documentation, and the Performance Qualification (PQ) demonstrated that BSP Pico fully meets and exceeds all requirements.

In summary, the project confirmed the key points requested by the client:

• Traceability: UDI marking generated from SQL database codes, compliant with FDA and EU MDR.
• Versatility: 5 product families on a single machine, 4 tested materials.
• Repeatability and precision: medical-grade blackening, minimal deviation in multiple placements.
• Legibility: excellent even after autoclave cycles.
• Automation: WH10 magazine with 10 trays, CVS, and Pattern Matching for unattended operation.

Sisma’s MODO Robot laser marking machine produces consistently high-quality markings on different areas of the same part and, thanks to the automatic gripper change, can also process different parts in the same cycle.

These are complex operations, but they become easy to program with the ROBO-PRO system.

What is ROBO-PRO?

ROBO-PRO is the simplified programming methodology developed by Sisma: the robot’s movements are automatically defined based on the configured laser processes.

What You Get Automatically with ROBO-PRO

• Automatic sequencing of robot movements, synchronized with laser processes.
• Automatic reordering of movements: if the order of the laser processes changes, the order of the robot movements changes accordingly.
• Exclusion of processes with a single click: the corresponding robot movements are automatically eliminated, optimizing cycle times.

No robotics experience required

With ROBO-PRO, programming is within the reach of any operator. There’s no need to generate paths or check for potential collisions: the software handles everything on its own, reducing setup time and the risk of errors.

In precision machining for third parties, operational flexibility and the reliability of welding systems are a strategic competitive advantage.

Meccanica Tecnica s.r.l. of Bastiglia (MO), a leading company in the precision engineering sector, needed to acquire high-performance industrial welding machines for the maintenance and repair of:

• Industrial Molds
• Bearings, shafts, and valve seats
• Turbine blades and high-stress components

The company’s primary goal was to cover the widest possible range in terms of the dimensions, weight, and geometries of hardened steel parts. To meet these manufacturing challenges, SISMA laser welding machines proved to be the winning technological choice.

The Advantages of Laser Welding

Laser welding offers significantly greater structural and operational benefits than traditional technologies, making it ideal for mold maintenance and micro-welding:

• Minimal heat input: During the deposition of the cladding material, the area affected by heat is extremely small.
• No deformation: deformation of the workpieces and metallurgical damage are either nonexistent or negligible.
• High mechanical strength: excellent structural integrity and high processing speed.
• Ultra-precise weld bead: ability to create millimeter-precise joints (down to a few tenths of a millimeter).
• Material versatility: excellent weldability on steel, aluminum, titanium, bronze, and copper alloys, as well as the joining of dissimilar materials (e.g., steel and copper).
• Cost-effectiveness: reduction in unit welding costs for high-volume production.

The SISMA Solution: Versatility and Software Automation

SISMA industrial laser welding machines are designed to ensure maximum accessibility even on the most complex geometries. They allow for easy operation in recesses, deep holes, sharp corners, edges, and grooves.

Using the intuitive software developed by SISMA, operators can create programmed welding paths that follow specific profiles and/or paths with regular shapes, such as circles or lines repeated at set intervals, etc.

Following a detailed analysis of the production processes and consultation with the SISMA engineering team, Meccanica Tecnica s.r.l. selected two fiber-based laser systems to cover the entire range of required machining operations:

SWA 450F

A fiber laser system specifically designed for mold repair and maintenance, ideal for depositing filler material on large surfaces and components.

SWT 450F

A high-precision laser welder, perfect for both general maintenance and precision micro-welding.

Why Choose Fiber Laser Technology Over Lamp-Based Lasers?

The integration of fiber-optic light sources into SISMA machines offers immediate operational benefits:

• Zero maintenance: drastic reduction in downtime and operating costs.
• Reduced focused spot: extremely small beam diameter, essential for corner joints and micro-welds.
• Higher average power: significant increase in deposition rate and welding speed on steel.

The SWA 450F and SWT 450F are machines that offer a high level of automation, but thanks to advanced visual inspection systems and an intuitive software interface, they are easy to use even for operators who are not highly specialized.