It is important to have the correct joint design and if this could be changed to suit robotic welding, it will be much easier to achieve success. The ideal joint is a fillet joint, but an overlap joint is also easy to weld. For thin gauge materials joint design and gap conditions become even more critical and it essential that the components are cut and bent with CNC equipment.
By modifying the joint design of an outside corner, it will be much easier for the robot to weld. Even if the integrity of an outside corner has to be maintained it would be helpful if the joint could be designed so there is a lap condition.
Butt joints on thin gauge materials represent a serious challenge for robot welding. By changing the design to an overlap joint the success rate can be dramatically improved.