Kaizen PLM delivers tailored post processors for MTC’s Fanuc Welding development Cell, enabling full offline programming and simulation in Siemens NX CAM.
Kaizen PLM delivers tailored post processors for MTC’s Fanuc Welding development Cell, enabling full offline programming and simulation in Siemens NX CAM.
Introduction:
The Manufacturing Technology Centre (MTC) is one of the UK’s leading advanced manufacturing research facilities. Established to bridge the gap between academia and industry, the MTC plays a key role in accelerating the development and adoption of cutting-edge manufacturing technologies, With a strong focus on innovation, collaboration, and workforce upskilling. The MTC supports companies of all sizes in developing and implementing smart, sustainable advanced manufacturing solutions. Their state-of-the-art facilities include high-tech robotic cells, additive manufacturing and laser processing labs and advanced machining centres, all dedicated to breaking boundaries and pushing the envelope in the advancement of modern manufacturing techniques and technologies.
The Challenge:
The MTC’s Fanuc Welding Development Cell includes three industrial robots, each equipped with various welding end effectors. Prior to working with Kaizen PLM, programming these robots was a manual, time-consuming process, lacking consistency and flexibility. The absence of an integrated offline programming solution meant that toolpaths couldn’t be validated before production, resulting in inefficiencies, inconsistent weld quality, and limited capability to handle complex weld paths or interpolate motions across multiple axes.
Manual, slow programming
Inconsistent weld quality
Unable to create toolpaths for complex welding tasks
In-depth analysis of MTC’s Fanuc Cell
Custom post processors for each robot
Siemens NX CAM integration
Welding-specific commands and interpolation enabled
Faster prototype cycle time
Simulated machine output illustrated via the robot cell digital twin
Eliminated manual edits across multiple part families.
The Solution:
Kaizen PLM collaborated closely with MTC to analyze the configuration and welding requirements of each robot in the Fanuc Welding Cell. A custom NX CAM post processor was developed for each robot, tailored to their specific end effectors and applications. In addition, Kaizen PLM created Machine Tool Smart Kits to replicate real-world robot behaviour within Siemens NX. These post processors enabled integration of interpolation movements and welding-specific commands directly within NX CAM, allowing MTC to simulate and validate complex toolpaths entirely offline. This solution streamlined programming workflows, reduced manual input, and delivered consistent, high-quality welds.
The Results:
The MTC can now program complex welding tasks offline with full integration in Siemens NX CAM, allowing for accurate simulation before real production. This has significantly improved welding consistency, reduced programming time, and streamlined overall workflows, enhancing productivity and quality assurance.
Looking Ahead:
Kaizen PLM will continue to support the MTC by advancing post processor customization and simulation capabilities for their Fanuc Welding Cell, helping MTC maintain its leadership in robotic manufacturing and process innovation.
Solutions/Services:
NX CAM Post Processor Development
6-axis Fanuc Welding Robot integration
Post Debugging & Optimization
Simulation-Driven Manufacturing Consulting