The plastics and composites industry is facing growing challenges: a shortage of skilled labour, increasing pressure to reduce costs and environmental impacts, and the need to maintain consistently high product quality. More recent issues, such as the loss of work permits for some foreign workers, have further intensified the labour shortage.
Robotics and automation offer an effective response to these challenges. They not only optimize production but also reduce dependence on a large workforce. Moreover, they can now deliver a significant return on investment within a relatively short period. The following examples of automated and robotic cell implementations in companies operating in the composites sector illustrate how these technologies can transform manufacturing processes in ways that are both practical and accessible for small and medium-sized enterprises (SMEs).
Partial Automation: A Cost-Effective Solution for Variable Parts and Small Production Runs
The integration of a reciprocating polyester resin applicator for manufacturing composite panels is an excellent example of partial automation tailored to specific production needs. Although designed for a relatively modest application, it demonstrates how innovative automation can deliver substantial benefits.
This system was developed for a manufacturer producing custom parts on demand. Because production setups must be continuously adjusted to accommodate different products, a fully automated solution was neither practical nor economical. Partial automation proved to be the ideal approach. It also represents an excellent first step toward a gradual automation and robotics strategy, enabling manufacturers to adopt new technologies progressively while preserving the flexibility required for custom manufacturing.
The custom-designed equipment, developed in close collaboration with the customer, is capable of applying resin and fiberglass over an area measuring up to 60 feet long by 10 feet wide, while fully complying with safety standards for hazardous (explosive) environments. The system uses resin spray equipment supplied directly from totes and features a wireless operator interface that allows users to configure resin application rates per square foot and adjust process parameters as needed, providing maximum operational flexibility.
Naturally, a technological development of this nature involves significant engineering challenges. However, these challenges are rarely insurmountable. The results achieved by the customer clearly demonstrate the value of the solution. Resin application is now highly consistent and exceeds the targeted performance objectives, generating annual raw material savings of approximately $100,000 while reducing the workforce previously required for the operation by four employees. Once the production parameters for each part are entered into the operator interface, the system operates autonomously and safely, allowing employees to focus on other value-added tasks. This eliminated a major production bottleneck and doubled manufacturing capacity.
The benefits extend well beyond savings in labour and raw materials. By connecting the equipment’s control interface to the company’s ERP database, manufacturers can archive production records while tracking, in real time, raw material consumption, batch traceability, and key process parameters such as ambient temperature, catalyst percentage, and resin spray pressure. This connectivity also makes it possible to correlate product defects with manufacturing conditions, providing valuable insights into root causes and corrective actions.
Furthermore, the resulting production database lays the foundation for predictive process optimization. Over time, manufacturers can anticipate the optimal process settings based on variables such as seasonal changes, which can significantly influence resin curing and polymerization. Instead of reacting to problems after they occur, manufacturers can proactively optimize production—a capability made possible by automated systems that retain and consistently apply process knowledge, unlike human operators, who may occasionally overlook or forget critical details.
Combining Robotics and R&D for Maximum Impact
The robotic application of gel coat and fiberglass in the production of large composite parts is an excellent example of a successful digital transformation that enables more efficient and precise manufacturing.
For this project, the renowned robot manufacturer Fanuc authorized, for the first time, the use of its P-700iB robots for an industrial application other than paint spraying—adapting them specifically for fiberglass spray-up.
The system integrates two synchronized long-reach robots. The technological approach was designed to address the challenges associated with manufacturing very large components and the short curing time of thermoset resins. Each robot is equipped with a custom-adapted six-strand fiberglass chopper gun specifically configured for this process. To meet the short lamination window required for oversized parts and ensure that resin curing does not begin before lamination is complete, the system was designed to deliver a resin flow rate of 15 kg/min per robot.
Another important advantage is that the robotic trajectories can be programmed offline using specialized simulation software. As a result, the system can be implemented and commissioned without disrupting the existing production line. Manufacturers can therefore automate and robotize their production processes smoothly while maintaining ongoing operations.
The two robotic cells have significantly reduced cycle times. In this particular application, they tripled production capacity by eliminating the bottleneck previously created by manual spray-up operations, while generating annual raw material savings of approximately $45,000. In addition, automation ensures consistent material thickness, eliminates process variability, and improves overall part quality.
The benefits of process optimization extend well beyond productivity gains. By optimizing material usage and reducing waste, the robotic system also significantly lowers the company’s environmental footprint, contributing to more sustainable manufacturing.
Integrating scientific research and experimental development (SR&ED) into the automation and robotics project also enabled the company to benefit from substantial tax incentives. By investing in SR&ED projects, manufacturers can explore innovative technologies and manufacturing methods while reducing the financial burden associated with research and development. This approach helps de-risk automation investments and fosters a culture of continuous innovation—an essential competitive advantage in today’s rapidly evolving manufacturing landscape.
Benefits and Key Success Factors
These examples demonstrate that automation and robotics can provide manufacturers with practical, cost-effective solutions tailored to their specific operational challenges. By reducing scrap, lowering raw material consumption, and increasing manufacturing flexibility, companies can not only improve their financial performance but also reduce their dependence on labour and minimize their environmental footprint, all while strengthening their competitive position.
However, the success of an automation or robotics project depends on close collaboration between the manufacturer and the system integrator. This partnership is essential to fully understand the manufacturer’s specific requirements and develop customized solutions that meet those needs. It is equally important for the customer to play an active role throughout the development process—not only to ensure that the system aligns with its operational objectives, but also to gain a thorough understanding of how it functions. This involvement facilitates user adoption and makes the transition to automated production significantly smoother.
Contrary to common misconceptions, implementing automated and robotic systems is often far less complex than it appears. With the guidance of an experienced integrator, manufacturers can quickly become self-sufficient in operating and maintaining their systems, avoiding excessive dependence on technology suppliers while achieving a tangible return on investment within a relatively short timeframe.
In addition, numerous government funding programs are available to support companies financially and technically as they adopt advanced manufacturing technologies. These programs help reduce implementation costs while encouraging innovation and the adoption of modern, high-performance solutions.
Above all, by reducing waste and streamlining manufacturing processes, automation enables the industry to achieve a sustainable balance between environmental responsibility, operational efficiency, and long-term competitiveness.
By Alain Deslauriers, special collaboration
Alain Deslauriers is co-owner of Lory Automation (adeslauriers@loryautomation.com).
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