Articulated Robots in Manufacturing: Benefits, Applications, and Trends

Robotics has transformed the manufacturing landscape over the past few decades by automating a vast array of tasks, significantly enhancing efficiency, safety, and accuracy. The term ‘robotics’ covers a multitude of different technologies, but one of the most influential types of industrial robots widely used in UK manufacturing today is the articulated robot. From automotive assembly lines to electronics and food production, articulated robots provide a robust and reliable solution for automating key tasks, proving to be an essential tool for achieving agile and efficient manufacturing.

What Is an Articulated Robot?

Different Types Of Robotic Applications

An articulated robot is a type of industrial robot that resembles a human arm. It is characterised by multiple rotary joints, also known as revolute joints, which can range from two to ten or more, although the most common types of industrial models typically feature four to six axes. These interacting joints allow the articulated arm robot a wide range of motion and freedom of movement. These joints enable the robotic arm to move with exceptional flexibility and reach, allowing it to perform complex tasks such as arc welding, assembly, painting, material handling, and packaging. They typically have a higher payload than other rigid robot types, such as standard delta robots or SCARA robots, and can handle goods of 1000+kg depending on the robot model deployed.

Articulated robots consist of a number of key components, from the base that anchors the robot and multiple joints, to end effectors or end-of-arm tooling such as grippers or welding torches, and sensors or vision software that allow the robot to detect positioning and carry out vision inspection tasks. Articulated robots are controlled by sophisticated software systems and a robot controller that guides their movement through pre-programmed paths or via real-time sensor input. The controller calculates the required joint movements needed to place the end effector precisely where it’s needed to carry out the task effectively. These robots can work autonomously or, as technology continues to advance, making them more perceptive to their surroundings, articulated robots are becoming more collaborative, depending on the application and safety setup. Some six-axis articulated welding robot systems are even capable of integrating with autonomous mobile robots to streamline factory workflows.

Benefits of Articulated Robots in Manufacturing

Articulated robots offer a wide range of advantages with their ability to perform precise, repetitive, and complex tasks. Here is an outline of the key benefits:

Precision and Consistency

Articulated robots can perform intricate tasks with high levels of repeatability, eliminating human error and variability.

Increased Productivity

Robots can operate 24/7 without fatigue, dramatically increasing production output and becoming some of the fastest robots on the production line.

Cost Efficiency

While initial investment can be high, long-term savings in labour costs, waste reduction, scalability, and process efficiency often lead to more positive ROI.

Flexibility

A single articulated robot can handle multiple tasks from welding to inspection by changing the end effector or programming, often outperforming a wrongly selected robot solution in terms of efficiency.

Workplace Safety

Robots handle dangerous, repetitive, or physically demanding tasks, reducing the risk of fatigue or injuries to workers. Sealed joints and joint structures also enhance safety in harsh environments.

Adaptability to Complex Designs

Especially useful in industries with customised or varied product designs, such as the aerospace and automotive sectors, where flexibility is critical. This versatility makes articulated robots a strong choice across the robot spectrum.

As highlighted above, the benefits of articulated robots are extensive, not only delivering increased output but also contributing to safer workplaces, reduced operational costs, and greater manufacturing agility.

Applications Across Industry Sectors

Articulated robots have become indispensable thanks to their versatility, precision, and adaptability. Their ability to perform tasks as wide-ranging as car assembly to vial filling with high levels of efficiency makes them ideal for sectors where precision and regulatory adherence are vital. Below are some of the key industries where articulated robots are making a considerable impact:

Automotive – the largest adopter of articulated robots. Common robot applications include welding car frames, installing windshields and parts, painting and coating using paint robots, as well as precision assembly using six-axis robots.

Electronics – with applications requiring high levels of precision, articulated robots are widely used for PCB assembly, soldering micro components, and handling delicate, small parts with accuracy.

Food & Beverage – a reliable solution for a wide range of applications. Robots are typically used in the food and beverage sector for packaging and palletising, sorting products, and quality inspection using hygiene-rated robots and advanced vision software.

Aerospace – strict requirements for precision engineering can be achieved using articulated industrial robots. These are used for drilling and fastening, surface finishing and coating tasks, as well as handling composites.

Pharmaceuticals and Medical Devices – also highly regulated. The pharmaceuticals and medical devices industries have adopted articulated robots for a wide range of tasks, including cleanroom packaging, filling vials and syringes, and assembly of medical instruments.

General Manufacturing – due to their robust and flexible capabilities. General manufacturing tasks include applications such as CNC machine tending, material handling and sorting, and quality inspection using AI and vision systems.

These diverse applications demonstrate the flexibility and scalability of articulated robots across a range of manufacturing sectors. From enhancing quality control in electronics or increasing productivity in food processing, their role supports companies as they strive to achieve greater efficiency, safety, and agility in a dynamic and challenging marketplace.

Trends in the Use of Articulated Robots

Articulated robots started their industrial life carrying out simplified tasks limited by early know-how. However, times have changed, and as technology continues to evolve at a significant pace, so too does the role of articulated robots in manufacturing, which is now rapidly expanding into new sectors, driven by advances in AI, connectivity, and human-robot collaboration. Many successful robot projects today involve 6-axis articulated robots or hybrid deployments involving Cartesian robots, SCARA robots, and legged robots.

The following trends highlight how articulated robots are adapting to meet the changing demands of modern manufacturing, where robot automation is key to addressing labour shortages and enhancing productivity and overall efficiency:

Collaborative Robotics (Cobots)

Modern articulated robots are becoming safer and more collaborative, increasingly deployed to work side-by-side with humans on shared tasks.

AI and Machine Learning Integration

Robots are increasingly being equipped with AI vision systems for quality inspection and adaptive learning, allowing for more autonomous decision-making.

Robotics-as-a-Service (RaaS)

This model offers flexible access to automation with monthly subscriptions, making robotics even more accessible to SMEs.

Sustainability and Green Manufacturing

Articulated robots help reduce waste and energy use through process optimisation, supporting sustainability and green manufacturing targets.

UK Market Growth

According to the British Automation & Robot Association (BARA), robot sales in the UK increased by over 30% in 2024, driven by skills shortages and demand for reshoring. The UK’s automotive sector accounts for nearly 50% of industrial robot installations, and there is a rising adoption of articulated robots in food production and logistics, contributing to the growth of the articulated robot market.

Low-Cost and Modular Robots

Affordable articulated robots are now available for small-batch or niche manufacturing, often with plug-and-play integration and user-friendly programming, further supporting businesses starting their articulated robot project.

A Case for Competitive Advantage

Articulated robots offer significant benefits to manufacturing, delivering enhanced precision, flexibility, and efficiency across numerous applications.

As technology advances and costs continue to fall, an increasing number of small and mid-sized UK manufacturers can embrace robotic automation as a viable solution to enhance operations, support growth, and remain competitive for the long term.