Assembly Automation


We have gained a wealth of experience in planning and implementing industrial assembly systems and obtained results from numerous research projects on assembly automation with robot systems. We develop for you and in collaboration with you, fully-automated or partially-automated solutions tailored to your assembly requirements.


  • Identification of technically- and economically-feasible automation potentials in your assembly
  • Development of innovative assembly processes and corresponding tools and systems for your assembly tasks
  • Process assurance by means of feasibility studies in our optimally-equipped assembly laboratory
  • Design of partially- and fully-automated assembly lines for your products, taking your specific general requirements into account
  • Development of software solutions for controlling assembly processes and analyzing the necessary sensor data

Technologies and innovations

  • Sensor-controlled joining processes using force-torque sensors and 2D and 3D cameras
  • Safety concepts and interaction concepts for assistive robots to enable human-robot collaboration
  • Programming methods and user interfaces for intuitively programming assembly tasks
  • Assembly of flexible components


  • Lower costs through automation
  • Reproducible high quality
  • Increased manufacturing capacity
  • Enhanced ergonomics through reduction of physical stress on workers

Analysis of Automation Potentials in Assembly Processes

Fraunhofer IPA has developed the Automation Potential Analysis (APA) for this very purpose. Using a range of criteria, the automation experts examine the different assembly steps (separation, handling, positioning and joining) in terms of their “Fitness for Automation”, before weighting these various criteria according to customer requirements.

Assembly Processes and Tools

In order to automate assembly tasks, a tailored suitable automation process has to be developed in line with the necessary assembly tools.

Sensor-Controlled Assembly

Integrating sensors into robot systems for assembly allows positioning and component tolerances to be compensated for, thus doing away with the need for expensive component-specific devices for defining the position of parts.

Safe Human-Robot Collaboration with Assistive Robots

Assistive robots, i.e. robots that share the working environment with humans, enable assembly tasks to be partially automated even in cases where full automation is not economically practicable.

Automatic Component Analysis with NeuroCAD

The web-based software NeuroCAD automatically analyzes specific component properties, such as how easy a component can be separated or picked up.

pitasc: Programming Assembly Processes in a Structured and Modular Way

With the pitasc modular system, applications can be implemented quickly and flexibly with the help of ready-made program modules, designed robustly thanks to force control, and easily adapted to new product variants via parameters.


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Automation Potential Analysis-App (APA-App)

Assistive robot for riveting operations

Vollautomatische Applikation von selbstklebenden Türdichtungen mit Roboter

Konzeptstudie zur Mensch-Roboter-Kooperation zur Applikation einer selbstklebenden Türdichtung

Sichere Mensch-Roboter-Kooperation in der Montage

SMErobotics Trailer Video

Nieten, schrauben, klipsen: Viele Anwendungen. Eine Lösung.

INSITU – Intuitive und sichere Bedienung und Steuerung von Roboterassistenten


Product sheet “Assistive robots for assembly operations”

Product sheet “Automation potential analysis for assembly processes”

Product sheet »Assessing the potential to automate assembly processes«

Product sheet “Assembly planning: we'll develop your automation solution”

Product sheet »Implementing robot applications safely with and without HRC«