Welding Robots Yaskawa, KUKA, FANUC — Comparison for Buyers

Automating welding with robots is one of the most profitable investments in metal fabrication. A new welding cell (robot + positioner + power source + fencing + programming) costs 120 000-300 000 EUR. On the German second-hand market, complete systems appear for 25 000-80 000 EUR — but brand choice and configuration have a major impact on total cost of ownership.

Hutnia regularly assists in the purchase of used welding robots. Below we compare the three dominant brands on the European market.

Yaskawa Motoman: The Welding Specialist

Yaskawa (formerly Motoman) built its reputation primarily in welding.

Common models: MA1440 (6 kg payload, 1 440 mm reach — successor to MA1400), AR1440/AR2010 (newer series), HP20D (older but widespread). Most common on the used market: MA1440 and HP20D.

Controller: DX200 (current) and DX100 (predecessor). DX100 used: 3 000-6 000 EUR as exchange unit. DX200 rarer: 8 000-15 000 EUR.

Used prices: Complete cell Motoman MA1440 + DX200 + Fronius TPS 400i + 2-axis positioner: 35 000-65 000 EUR. Robot with controller only: 12 000-25 000 EUR.

Strengths: Best welding algorithms in the industry (dedicated MIG/MAG, TIG, CMT functions). Integrated interfaces to all major power sources (Fronius, Lincoln, Miller, SKS). Low self-weight (50 kg for MA1440) — easy mounting even on a gantry.

Weaknesses: Smaller service network in Central Europe than KUKA. Inform programming (Yaskawa's proprietary language) less intuitive than KRL for those coming from European robots.

KUKA: The German Automotive Standard

KUKA dominates the German automotive sector. On the used market, KUKA is the most readily available brand — liquidations from the automotive industry are the main supply source.

Common welding models: KR 6 R900 sixx (compact), KR 8 R1620 (8 kg, 1 620 mm), KR 16-2 (older standard, still common). The KR CYBERTECH nano series (KR 6/8/10 R1420-R1820) is the current line.

Controller: KR C4 (current), KR C2 (older — avoid, limited capability and no support). KR C4 used: 5 000-10 000 EUR.

Used prices: Cell KUKA KR 8 R1620 + KR C4 + Fronius TPS 320i + DKP-400 positioner: 30 000-55 000 EUR. Robot with KR C4 alone: 10 000-22 000 EUR.

Strengths: Largest service network in Europe. KRL programming well documented. Huge pool of programmers (high automotive penetration). KUKA.ArcTech — welding package with path visualization. WorkVisual (offline programming) mature.

Weaknesses: KUKA welding robots are slightly heavier than Yaskawa (KR 8 R1620: 54 kg vs. MA1440: 50 kg). KUKA.ArcTech software license must be purchased separately (2 000-4 000 EUR).

FANUC: Japanese Reliability

FANUC is the world's largest robot manufacturer by installed base. In welding, the ArcMate series dominates.

Common models: ArcMate 100iD (12 kg, 1 441 mm), ArcMate 120iD (25 kg, 1 831 mm — for heavy torches), M-10iA/12 (older, still circulating). On the German used market: ArcMate 100iC/iD and M-10iA.

Controller: R-30iB Plus (current), R-30iB (previous — still solid), R-30iA (older — check parts availability). R-30iB used: 6 000-12 000 EUR.

Used prices: Cell FANUC ArcMate 100iD + R-30iB Plus + Lincoln PowerWave + positioner: 30 000-60 000 EUR. Robot with controller alone: 12 000-28 000 EUR.

Strengths: Legendary reliability (MTBF over 100 000 h per manufacturer). iRVision (machine vision) integrated — relevant when welding parts with tolerances. FANUC Arc Tool — dedicated welding package. Very good support across Europe.

Weaknesses: Teach Pendant interface less modern than KUKA smartPAD. TP programming (FANUC) is low-level — less readable than KRL. Spare parts prices higher than competitors (FANUC servo motor: 3 000-6 000 EUR vs. KUKA: 2 000-4 000 EUR).

Power Source: The Critical Cell Component

The robot is just the manipulator. Weld quality depends on the power source:

Fronius TPS/i — Austrian standard, most common in German cells. TPS 400i (pulse MIG/MAG): new 8 000-12 000 EUR, used 3 000-6 000 EUR. Excellent integration with all three robot brands.

Lincoln PowerWave — American standard, popular with FANUC. PowerWave 455M used: 2 500-5 000 EUR.

SKS Welding — German company, integrated torches, common with KUKA in automotive. Specialized and more expensive.

EWM — German manufacturer, Phoenix/Titan series. Less common in robotic cells but valued for TIG welding.

Key rule: buy the cell with its original power source. Swapping the source requires reprogramming all welding parameters — integration cost: 3 000-8 000 EUR.

Positioner: The Forgotten Half of the Cell

The positioner (rotary / tilt-rotary table) accounts for 30-40 % of a complete cell's value. Types:

• Single-axis (L-positioner): 360-degree rotation. Used: 3 000-8 000 EUR. Sufficient for simple structures.
• Two-axis (DKP): rotation + tilt. Used: 8 000-20 000 EUR. Standard for 3D welding.
• H-positioner (headstock-tailstock): for long parts (frames, beams). Used: 10 000-25 000 EUR.

Check points: gearbox backlash (dial indicator test), bearing condition, load capacity (typically 250-1 000 kg).

Learn more about industrial robots in general and KUKA robots in detail in our guides.

Next Step With Hutnia

Buying a used welding cell is a project, not a one-off transaction. Hutnia verifies robot condition (calibration protocol, operating hours), power source (arc test) and positioner (backlash, load capacity). We organize dismantling, transport and commissioning support.

Book an initial consultation Step 0 for EUR 49 — fully deductible from the EUR 500 mandate. Schedule now.