Development of a Dual-Arm Robotic Cell for Automated Manufacturing of Variable-Geometry Thermoplastic Composite Ducts

This research focuses on the development of a robotic cell test bench for manufacturing variable-geometry tubular parts with minimal manual intervention. The system integrates dual-arm manipulation with cutting and laser-welding stations and was evaluated in collaboration with an industrial partner with strict requirements on joint strength and sealing performance. The experimental investigation characterized the influence of key welding process parameters, particularly the robot end-effector travel speed (mm/s) and laser power (W), on the mechanical performance of the welded joints. These parameters were subsequently used to manufacture representative three-dimensional duct geometries. In addition, preliminary sealing evaluations were used to assess the ability of the welded components to withstand internal pressures. These results highlight the influence of mechanical components, geometries, and material behavior, as well as the need for advanced digital tools. A preliminary automated path-generation methodology is introduced to support adaptable robot trajectories. Overall, the results support the feasibility of the integrated robotic manufacturing concept while identifying the additional developments required before fully automated production can be achieved.