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 human intervention. The system integrates dual arm manipulation with cutting, welding, and coating stations, and was validated in collaboration with an industrial partner with strict requirements on weld strength, surface quality, and air leak rate. Stable and repeatable operation of the robotic cell was achieved through the characterization and optimization of key welding process parameters, particularly the robot end-effector travel speed (mm/s) and laser power (W). In addition, preliminary sealing evaluations demonstrated that the welded components could 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. This research aims to advance composite manufacturing using industrial robotics and dedicated tooling for complex processes, while inspiring engineers and researchers to further automate repetitive and labour-intensive tasks that remain challenging to robotize.