Robotics Applications

What We Do

Core Services

End-to-end onsite robot services designed to keep your production line running at peak efficiency.

Onsite Robot Programming

Expert robot programming at your facility — from new cell commissioning to complex path refinement, all without disrupting production.

New program development & commissioning
Path optimisation & cycle time reduction
Offline programming (Roboguide, KUKA.Sim, RobotStudio)
Multi-robot coordination & synchronisation

Troubleshooting & Support

Rapid fault diagnosis and resolution to minimise costly unplanned downtime. Our engineers arrive prepared for first-visit fix rates.

Alarm diagnosis & fault history analysis
Controller & servo drive troubleshooting
Wiring, I/O, and PLC interface faults
Remote & onsite emergency support

Preventive Maintenance

Scheduled maintenance programs that extend robot service life, prevent failures, and keep warranties valid.

OEM-compliant scheduled servicing
Battery, grease, and filter replacement
Mechanical wear & backlash inspection
Mastering verification & recalibration

System Optimisation

Unlock hidden capacity by fine-tuning robot motion, payloads, and program logic for measurable OEE improvements.

Cycle time & throughput analysis
Payload & inertia optimisation
Energy-saving motion profiles
Line balancing & bottleneck elimination

Safety System Integration

Design and integration of robot safety systems compliant with AS/ISO 10218 and TS 15066 for collaborative deployments.

Safety-rated PLC & safety controller setup
Guarding design & area scanner integration
Risk assessment & safety validation
Human-robot collaboration (HRC) zones

Plant Integration

Seamless integration of robot cells with PLCs, SCADA, MES, and Industry 4.0 data infrastructure.

PROFINET, EtherNet/IP & DeviceNet
PLC handshaking & interlocking
OPC-UA data connectivity for MES/ERP
Production monitoring dashboards

Welding Applications

Precision Robotic Welding Solutions

Robotic welding delivers unmatched consistency, speed, and quality across automotive BIW, structural fabrication, and high-strength joining applications. Our engineers specialise in commissioning, programming, and optimising welding cells for maximum uptime and weld quality.

From multi-point spot welding with precise force control and real-time quality monitoring to adaptive arc welding seam tracking on steel, aluminum, and stainless — we cover the full spectrum of robotic welding processes.

Spot Welding (BIW): Multi-point welding with precise force control and real-time quality monitoring.
Arc Welding (MIG/TIG): Adaptive seam tracking and multi-pass welding on steel, aluminum, and stainless.
Laser Welding: High-precision for thin materials, minimal heat-affected zones.

Discuss Your Welding Cell

Painting & Finishing

Robotic Paint & Surface Finishing

Robotic painting and finishing applications demand precision, repeatability, and flawless surface quality. Our engineers program and optimise spray painting, powder coating, polishing, and deburring operations for consistent results across every part.

Whether it's consistent film thickness with rapid color changeover in automotive paint shops, electrostatic powder coating for complex geometries, or force-controlled adaptive path planning for mirror-finish polishing — we deliver programs that meet the strictest quality standards.

Spray Painting: Consistent film thickness and rapid color changeover.
Powder Coating: Electrostatic deposition for uniform coverage on complex parts.
Polishing: Force-controlled, adaptive path planning for mirror finishes.
Deburring: Force-controlled flash removal and edge-breaking on cast parts.

Explore Finishing Solutions

Material Handling

Efficient Robotic Material Handling

Material handling is the backbone of automated production — and robotic solutions deliver the speed, flexibility, and reliability that modern logistics demands. From vision-guided pick-and-place to complex bin picking and palletizing, we design and program systems that keep your line moving.

Our expertise spans delta, SCARA, and 6-axis configurations for pick-and-place, 3D vision deep-learning for unstructured random bin picking, mixed-product palletizing with slip-sheet logic, and conveyor tracking synchronisation for continuous-flow operations.

Pick & Place: Vision-guided delta, SCARA, and 6-axis configurations.
Bin Picking: 3D vision deep-learning for unstructured random bin picking.
Palletizing: Mixed-product stacking with slip-sheet and layer-by-layer logic.
Conveyor Tracking: Line-tracking synchronisation — no stops, no bottlenecks.

Optimise Your Material Flow

Advanced Process Expertise

Robotics Process Applications

Comprehensive robotic process solutions across sealing, assembly, cutting, inspection, and foundry applications for maximum industrial efficiency.

Sealing & Dispensing

Automated adhesive, sealant, and coating applications with precision bead control.

Adhesive Dispensing: Volumetric control for bonding, windshields, and panel joining.
Seam Sealing: PVC/polyurethane sealant for waterproofing and corrosion protection.
Underbody Coating: Uniform anti-corrosion spray on complex underbody geometries.
FIPG Gasket: Engine, transmission, and enclosure gasket-in-place application.

Assembly Operations

Precision robotic assembly, fastening, press-fit, and component mounting solutions.

Screw Driving: Torque-angle controlled fastening to specification.
Press Fit: Force-displacement curve analysis for bearings, seals, and pins.
Collaborative Assembly: Force-limited cobots alongside operators.
Clip Mounting: Vision-guided grommet, clip, and trim component insertion.

Cutting & Machining

Robotic laser, plasma, waterjet cutting, and CNC milling for precision material processing.

Laser/Plasma Cutting: 5- and 6-axis cutting heads with offline programming.
Waterjet: Cold-cutting for heat-sensitive composites, glass, and stone.
Robotic Milling: Large-envelope routing up to 60,000 RPM spindle speeds.
Drilling & Riveting: Stack drilling and automated rivet insertion for aero/auto.

Inspection & Quality

Vision-based inspection, precision measurement, and AI-powered defect detection.

2D/3D Vision: Structured light and laser triangulation for inline QC.
AI Defect Detection: Deep-learning classifiers for real-time accept/reject.
NDT: Ultrasonic, eddy current, and X-ray positioning systems.
Data & Traceability: SPC integration with MES/ERP for full traceability.

Foundry & Heavy Apps

Rugged robotic solutions for die casting, forging, heat treatment, and furnace operations.

Die Casting: Heat-resistant robots for ladle pouring, quenching, and trimming.
Forging: Billet loading and press transfer in extreme shock environments.
Heat Treatment: Precise furnace loading for hardening/carburizing cycles.
Fettling & Grinding: Adaptive gate removal and surface grinding.

Our Approach

How We Deliver

A structured, proven approach from initial assessment to ongoing support — ensuring every robot cell performs at its best.

01

Assessment & Diagnostics

We begin with a thorough assessment of your robot cell — reviewing fault history, cycle times, safety systems, and integration points.

Comprehensive cell health audit
Fault history and alarm analysis
Performance baseline measurement

02

Strategy & Planning

We define the scope, timeline, resource requirements, and success criteria — with full transparency on costs and expected outcomes.

Detailed scope of work document
Project timeline with milestones
Risk assessment and mitigation plan

03

Onsite Execution

Our certified engineers execute the work on-site — programming, troubleshooting, maintenance, or integration — with minimal production disruption.

Expert onsite engineering team
First-visit fix rate focus
Real-time progress communication

04

Validation & Handover

Every deliverable is validated against agreed criteria — cycle times, weld quality, safety compliance — with full documentation and operator training.

Performance validation report
As-built documentation and guides
Operator training and knowledge transfer

Robot Brands We Support

Multi-Brand Expertise

Our engineers are certified across all major industrial robot brands — your equipment, our expertise.

ABB

KUKA

FANUC

Yaskawa

Nachi

Kawasaki

Staubli

Universal Robots

Omron

Epson

Denso

Comau

Sector Spotlight

Automotive-Specific Applications

As a major sector for our operations, we provide specialised robotic integration designed for the rigorous, high-volume demands of automotive manufacturing — from BIW through to final assembly and inspection. Our engineers hold active service agreements with leading OEMs and have operated across Tier-1 supplier plants throughout Australia.

BIW Spot Welding Lines Multi-gun resistance welding for body-in-white structures with electrode management and force monitoring.
Robotic Sealing in Car Body PVC and polyurethane seam sealing for waterproofing, corrosion protection, and NVH requirements.
Engine & Transmission Assembly Precision fastening, press-fit, and FIPG gasket application for powertrain component assembly.
Robotic Inspection Systems End-of-line 3D vision and AI defect detection for paint finish, weld quality, and assembly completeness.

Key Capabilities

What Sets Us Apart

24/7 Support365 days a year

Certified EngineersOEM-trained specialists

On-Site Same DayMetro & regional

90-Day WarrantyAll workmanship

OEE ImprovementMeasurable gains

ISO 10218Safety-first approach

Root-Cause AnalysisFix right, first time

Full DocumentationAs-built & guides

Fieldbus ExpertsPROFINET · EtherNet/IP

Operator TrainingTheory & hands-on

Proven Results

Case Studies

Real challenges. Real solutions. Real results.

FANUC Welding Cell Recovery

Tier-1 Automotive Supplier

Challenge: Intermittent weld quality issues causing rejects. Solution: Onsite engineer identified corrupted mastering routine and recalibrated all 6 axes with force monitoring validation.

Result: Zero weld defects within 4 hours of onsite arrival.

Palletizing Line Throughput Boost

FMCG Distribution Centre

Challenge: Palletizing cell running 20% below target. Solution: Motion profile optimisation, payload recalibration, and conveyor tracking synchronisation.

Result: 28% throughput increase without hardware changes.

Safety System Upgrade & Compliance

Metal Fabrication Plant

Challenge: Non-compliant robot cell safety systems. Solution: Full safety redesign with area scanners, safety PLC, and ISO 10218 validation.

Result: Full compliance achieved with zero production downtime during upgrade.

Client Feedback

What Our Clients Say

"Prime's team had our Fanuc welding cell back online within four hours of the call. Their onsite programmer identified a corrupted mastering routine that had been causing intermittent rejects for months. Outstanding knowledge, zero fuss."

— Plant Manager, Tier-1 Automotive Supplier

Industries Supported

Trusted Across Every Sector

Our robotics engineers have experience across manufacturing's most demanding environments.

Automotive & Tier-1

Food & Beverage

Pharmaceutical

Metal Fabrication

Warehousing & 3PL

Plastics & Rubber

Electronics Assembly

Chemical Processing

Defence & Aerospace

Recycling & Waste

Common Questions

Frequently Asked Questions

What robot brands do your engineers support?

Our engineers are certified across all major industrial robot brands including ABB, KUKA, FANUC, Yaskawa/Motoman, Nachi, Kawasaki, Staubli, Universal Robots, Omron, Epson, Denso, and Comau. We also support collaborative robots (cobots) and delta/SCARA configurations.

How quickly can you respond to an emergency breakdown?

We offer same-day onsite response for metro and regional areas, with remote troubleshooting available immediately. Our 24/7 support line ensures you can reach an engineer whenever you need us — 365 days a year.

What warranty do you provide on your work?

All our workmanship comes with a 90-day warranty. If any issue arises related to our work within that period, we'll return to resolve it at no additional cost. We stand behind the quality of our engineering.

Do you offer preventive maintenance contracts?

Yes. We offer scheduled maintenance programs tailored to your robot fleet, OEM service intervals, and production schedule. Contracts include priority response, discounted rates, and comprehensive maintenance documentation to keep warranties valid.

Can you help with robot cell safety compliance?

Absolutely. We specialise in robot safety system design and integration compliant with AS/ISO 10218 and TS 15066. Our services include risk assessment, safety-rated PLC setup, guarding design, area scanner integration, and full safety validation documentation.

Do you provide operator training as part of your service?

Yes. Every project includes operator training and knowledge transfer. We provide both theory and hands-on training covering robot operation, basic troubleshooting, safety procedures, and program modification — ensuring your team is confident and self-sufficient.