Ultrasonic Welding Cell – Reno, NV

Designed and delivered four fully automated robotic ultrasonic welding systems that pick left- and right-hand components from vertical input towers, load them into a welding fixture, initiate the welding process, and transfer completed assemblies into shipping boxes. The system automatically monitors production status and signals operators when input towers require replenishment and shipping boxes need replacement.

Owned the project end-to-end, including solution development, mechanical design, electrical design, system assembly, commissioning, and onsite deployment. Successfully installed and launched four production systems at the customer facility in Reno, Nevada.

Results:

• Reduced staffing requirements from 5 operators to 2 operators per shift

• Supports 24/7 operation across 3 shifts per day

• Eliminated the need for 9 full-time operators per day

• Improved production consistency, throughput, and material handling efficiency through full automation

This project demonstrates full lifecycle automation engineering, from concept and design through deployment and production support.