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Electric vehicles are transforming the automotive industry, and ABB is helping lead that transformation with advanced robotics and automation technologies. During a tour of ABB’s North American Robotics Center in Auburn Hills, Michigan, Munro & Associates got a firsthand look at how ABB is deploying innovations like digital twins, AR/VR robot programming, flexible automation, and sustainable painting systems to support the evolving needs of EV manufacturers. We’ll unpack the insights from this visit and explore how ABB’s technology is shaping the future of automotive manufacturing.
Revolutionizing Factory Design with Digital Twins and VR
One of the standout capabilities demonstrated was ABB’s integration of RobotStudio VR with augmented reality. This setup allows engineers to step inside a virtual version of a factory cell and interact with the robot’s teach pendant, programming tasks in 3D space.
This immersive environment helps users understand spatial constraints and optimize layouts before any physical installation occurs. By simulating the entire robotic system—including PLCs and other hardware controllers—ABB enables full virtual commissioning of automated lines. The result: faster development cycles, improved safety, and reduced startup costs.
ABB’s team highlighted that digital twins are especially valuable for companies designing systems with lifecycle flexibility in mind. Startups and tech-forward OEMs are increasingly adopting this approach from day one, making digital twin integration a design standard rather than an afterthought.
Flexible Automation for a Changing Industry
As powertrain technologies diversify, automation systems must adapt. ABB is seeing significant demand for flexible, redeployable robotic assets—especially as OEMs shift between ICE, hybrid, and electric platforms.
The robotics center showcased a body-in-white welding cell with modular linear slides, positioning units, and ABB’s welding robots. These robots are equipped with internal dress pack management systems to reduce maintenance and maximize uptime—a key concern for manufacturing engineers managing cost-justification.
In addition, ABB’s Spot and Inspect system leverages ultrasonic sensors and AI algorithms to detect weld defects automatically. This shift from manual inspection to intelligent automation improves quality assurance while lowering labor costs—two factors critical in EV body assembly.
Adapting to EV Trends: Megacasting and Adhesive Bonding
The EV revolution is also bringing new joining technologies to the forefront. While traditional welding remains dominant in high-volume production, ABB engineers discussed the growing role of adhesives in low-volume EVs and the rise of megacasting—a technique popularized by Tesla.
ABB is preparing for this shift by offering robotic solutions for deburring, machining, and assembling large cast structures. As megacasting spreads beyond front and rear cradles into floorpans and other segments, flexible robotic applications will be essential.
Battery tray and cell manufacturing are also major focal points. ABB’s stamping and tray handling solutions—developed in Europe and now eyed for North American deployment—help customers scale battery production efficiently.
Collaborative Robotics and Small Business Accessibility
Beyond high-end manufacturing, ABB is also democratizing automation for small and midsize companies. One example is a MIG welding cart co-developed with Lincoln Electric. Designed as a plug-and-play system, the cart includes an integrated power supply and intuitive user interface.
With minimal training, an operator can guide the robot by hand, capture the motion path, and execute welds with a single button press. This entry-level system empowers smaller shops—such as off-road part manufacturers—to embrace automation without a steep learning curve or large capital outlay.
Collaborative robots (cobots) are another area of innovation. While not widely used in heavy-duty welding or body assembly, they are gaining traction in final assembly and kitting operations. With force feedback and flexible programming, cobots excel at handling lightweight parts and delivering just-in-time components on mixed-product lines.
PixelPaint: Sustainable, Precision Vehicle Painting
ABB’s push for sustainability was clearly on display with its PixelPaint system—an inkjet-style applicator mounted on a robotic arm. Designed for zero overspray, PixelPaint enables crisp two-tone paint jobs without the need for masking or multiple paint booth cycles.
In traditional operations, a two-tone finish often requires a vehicle to pass through the paint line twice, increasing energy use, labor, and emissions. PixelPaint eliminates this redundancy, reducing carbon footprint while delivering high-precision aesthetics.
Paired with high-efficiency bell atomizers that achieve up to 95% transfer rates, ABB’s paint technologies offer a path toward greener production in one of the automotive sector’s most polluting stages.
Magnet Placement Automation: Speed and Precision
Another fascinating application involved robotic magnet insertion for rotor assembly—a process critical to EV motor performance. ABB’s third-generation magnet loader and press machine automates what would otherwise be a slow, manual task.
By handling dozens of magnets simultaneously and pressing them into rotor cores, the system boosts throughput and consistency. As magnet geometry and placement become more important in high-efficiency motors, such automation proves vital for scaling EV drivetrain manufacturing.
Supporting Longevity and Lifecycle Cost Efficiency
ABB also emphasized their refurbishing and redeployment program. Many robots, including the first-ever built at the Auburn Hills facility in 2016, remain in service today. ABB supports lifecycle management by reconditioning used robots, issuing new warranties, and reintegrating them into new or existing production lines.
For cost-conscious engineers, this program reduces the total cost of ownership and provides a viable alternative to new equipment. Combined with predictive maintenance tools and modular dress pack designs, ABB robots aim for minimal downtime and extended service life—essential for justifying automation investments.
ABB Robotics Digital Twin Tech Takeaways
ABB’s Robotics Center isn’t just a showcase—it’s a blueprint for how automation can adapt to electrification, sustainability, and flexibility demands across the automotive industry. From full digital twin simulations to entry-level welding systems and sustainable paint processes, the message is clear: robotics are no longer optional—they’re foundational.
Whether you’re launching a new EV startup, upgrading a legacy factory, or looking to improve process reliability, ABB’s tools and expertise offer a robust starting point.
Stay Ahead with Munro’s Expert Analysis
For more insights into electric vehicle manufacturing, teardown analysis, and lean automation engineering, explore more content from the Munro team. Stay tuned to Munro Live for the latest on how technology leaders like ABB are shaping the automotive future—one robot at a time.