VITAWELD tackles one of the most persistent challenges in industrial manufacturing: welding large metal components without compromising quality, efficiency, or accessibility. Traditional processes struggle with heat-induced distortions, late detection of defects, and manual parameter adjustments that slow production and introduce variability. Programming industrial robots for such tasks requires advanced technical expertise, creating a barrier for companies with limited resources.
The solution brings a fundamentally different approach to welding automation
VITAWELD blends advanced computer vision, AI, and natural user interfaces to keep the operator in control while enhancing their capabilities. The system enables robot programming through natural language and real-time visualization in augmented reality, making adjustments intuitive and immediate. AI-powered vision algorithms detect potential defects as they happen, while automated parameter optimization ensures repeatability and minimizes waste. Built on a modular ROS 2 and FIWARE architecture, the platform can adapt to different industrial contexts and scale with changing needs.
Within the ARISE project, VITAWELD exemplifies how collaborative robotics can democratize access to advanced automation. FIWARE integration ensures interoperability and supports a standards-based approach, making the solution replicable across industries. Most importantly, it reflects a vision where technology empowers rather than replaces, aligning closely with the principles of Industry 5.0.
The impact is measurable
Early projections indicate a reduction of more than 50% in robot programming time, over 30% improvement in first-time-right weld quality, and the ability to train new operators in less than two days. Energy consumption could be reduced by 15%, with significant savings in material waste. These advances not only improve productivity but also make welding safer and less physically demanding, encouraging greater diversity in the workforce.
Market potential is equally strong
The global industrial human-robot interaction market is expected to reach $8.6 billion by 2025, with the large-component welding segment valued at $1.2 billion. By focusing on amplifying human capabilities rather than replacing them, VITAWELD differentiates itself from conventional automation. Its modular design and human-centered philosophy allow rapid adaptation to other processes such as TIG, MIG, and additive manufacturing, delivering a return on investment in just 18 to 24 months.
Inclusivity is embedded in the design
Interfaces are multilingual and configurable, with universal iconography and color-blind-friendly visualizations. Ergonomic considerations accommodate operators of different heights, handedness, and working styles. The system can adapt to local cultural norms in units of measurement, alerts, and training materials, ensuring usability across global manufacturing environments.
VITAWELD represents more than a technical solution—it redefines the relationship between people and machines in industrial welding. By combining precision, adaptability, and inclusivity, it sets a new standard for human-robot teaming, one where innovation strengthens human expertise, fosters sustainable manufacturing, and builds a safer, more productive future.