Towards Mixed-Reality-Based Robot Programming for a Welding Use Case

Industrial robot programming presents a significant bottleneck in modern manufacturing due to its complexity and reliance on expert knowledge, limiting production flexibility. This paper introduces an intuitive, user-centered method for programming industrial robots using Mixed Reality (MR). Our approach aims to lower the barrier to entry for non-expert users by enabling them to interact with a robot’s digital twin directly within the physical workspace. The proposed methodology consists of three distinct phases: (1) virtual planning - paths are defined on a real workpiece using a headset; (2) simulation and adjustment - the planned trajectories are visualized and refined to proactively detect and correct errors; and (3) real- world execution - the physical robot carries out the pre-validated program. We utilize a robotic welding use case to elaborate on how this method reduces programming complexity, minimizes setup times, and enhances safety. This research contributes to a more efficient and accessible paradigm for human-robot interaction, with future work focused on advanced sensor integration and compara- tive user studies to validate its effectiveness.