What Are Articulated Robots (6-Axis Robots)
Articulated robots, also known as 6-Axis robots, are industrial robots with rotary joints. This design allows them to move in multiple directions, similar to a human arm. They are widely used in manufacturing and automation because of their flexibility and range of motion.
What Is a 6-Axis Robot?
A 6-axis robot (also known as an articulated robot arm) is an industrial robot with six degrees of freedom (DoF), meaning it can move in six different ways—similar to a human arm. These movements include base rotation, shoulder, elbow, and wrist motions, plus wrist rotation and tilt. This allows the robot to position its tool at virtually any angle in 3D space.
Degrees of Freedom Explained
Each “axis” is a joint that adds motion:
- Base rotation (left/right)
- Shoulder (forward/back)
- Elbow (extend/retract)
- Wrist pitch (up/down)
- Wrist yaw (side-to-side)
- Wrist roll (rotation)
Together, these enable precise positioning and complex paths that simpler robots (like SCARA or Cartesian systems) cannot achieve.
Why 6-Axis Robots Are So Versatile
The flexibility of a 6-axis robot makes it ideal for:
- Handling irregular or complex parts
- Working in tight or angled spaces
- Performing multi-step tasks with one system
They can switch between tools (grippers, welders, cameras), making them suitable for both high-volume production and flexible automation—a key advantage for modern manufacturing.
Industries Using 6-Axis Robots
6-axis articulated robots are widely used across industries, including:
- Automotive: welding, painting, assembly
- Electronics: precision assembly and testing
- Food & packaging: pick-and-place, palletising
- Pharmaceuticals: cleanroom handling
- General manufacturing: machine tending and material handling
Whether you need precision, speed, or flexibility, a 6-axis robot is often the best all-around solution for industrial automation.
Compare 6-Axis Robots FANUC ABB KUKA Yaskawa
Key Differences Explained
1. Speed & Throughput
- FANUC and Yaskawa lead in high-speed production lines
- FANUC LR Mate can reach extremely high joint speeds and fast cycle times
- Best for: mass production, packaging, machine tending
2. Precision & Accuracy
- ABB IRB 120 is one of the most precise (±0.01 mm)
- Ideal for: Electronics and Small-part assembly
ABB dominates micro-precision automation
3. Balance (Performance vs Flexibility)
KUKA KR 6 offers:
- Strong balance of precision + speed
- Excellent software ecosystem
Best “all-round” industrial robot
4. Payload & Reach
Yaskawa GP7:
- Longest reach (~927 mm)
- Strong payload (7 kg)
Best for: Welding and Large work envelopes
| Attribute | FANUC LR Mate 200iD | ABB IRB 120 | KUKA KR 6 R700 | Yaskawa Motoman GP7 |
|---|---|---|---|---|
| Payload | 7 kg | 3 kg | 6 kg | 7 kg |
| Reach | 717 mm | 580 mm | 706 mm | 927 mm |
| Repeatability | ±0.01–0.02 mm | ±0.01 mm | ±0.03 mm | ±0.02 mm |
| Axis Speed | Very high (up to ~1500°/s joints) | Very high | High | Very high |
| Applications | Assembly, machine tending, pick & place | Electronics, micro-assembly | Precision assembly, automation | Welding, handling, palletising |
| Controller / Software | FANUC R-30iB / R-30B Plus | ABB IRC5 / RobotStudio | KUKA KRC4 / WorkVisual | Yaskawa YRC1000 |
| Robot Type | Industrial | Industrial | Industrial | Industrial |
Software & Ecosystem
| Brand | Strength |
|---|---|
| FANUC | Reliability, large install base |
| ABB | Simulation (RobotStudio) |
| KUKA | Engineering flexibility |
| Yaskawa | Welding & motion control |
Which 6-Axis Robot Brand Should You Choose?
When selecting a 6-axis articulated robot brand, focus on how well it meets your specific needs, budget, and system compatibility. A few major companies, known as the “Big Four,” dominate the market and account for over 50% of sales.
How a 6-Axis Articulated Robot Operates
When to use ABB:
- You need precision
- For electronics or small components
Choose KUKA if:
- You need dependable performance
- For adaptable automation
When to use Yaskawa:
- You require speed and reach
- For welding or material handling
Top 4 Robot Brands
Here are the most reliable and popular options:
🇯🇵 FANUC
🇨🇭 ABB Robotics
🇩🇪 KUKA
🇯🇵 Yaskawa Motoman
Decision Guide
Choose based on your needs:
- Max uptime & speed → FANUC
- Precision + software → ABB
- Complex integration → KUKA
- Budget-friendly → Yaskawa
How a 6-Axis Articulated Robot Operates
Here’s a clear, decision-focused cost & ROI analysis comparing manual labour vs. articulated (6-axis) industrial robots, structured the way a CFO or operations manager would evaluate it.
How a 6-Axis Articulated Robot Operates
1. Structure of a 6-Axis Robot
A 6-axis robot has six rotary joints (or axes) that enable movement in almost any direction within its workspace. It is comparable to a human arm, which includes a shoulder, elbow, and wrist, with additional rotational capabilities. The axes are defined as follows:
- Axis 1 (Base Rotation): Rotates the robot around its vertical base.
- Axis 2 (Shoulder): Moves the arm forward and backward.
- Axis 3 (Elbow): Extends or retracts the arm.
- Axis 4 (Wrist Roll): Rotates the wrist around the forearm.
- Axis 5 (Wrist Pitch): Moves the wrist up and down.
- Axis 6 (Wrist Yaw): Rotates the end-effector horizontally.
This setup allows for full 3D positioning and orientation of the tool at the robot’s “hand.”
2. Step-by-Step Operation Cycle
1. Programming
Engineers program the robot using teach pendant or offline software
Positions (points) and paths are defined
2. Path Planning
The controller calculates motion using robot kinematics
Ensures smooth, collision-free movement
3. Motion Execution
Motors rotate each axis simultaneously
Movements are coordinated for precise positioning
4. Feedback & Correction
Sensors continuously send data
Controller adjusts in real time (closed-loop control)
5. Task Execution
End effector performs the job (e.g., welding, picking)
Articulated Robots in Car Manufacturing
Articulated robots are essential in car manufacturing due to their precision and versatility. They effectively handle tight spaces and complex tasks such as welding and painting. Their adaptability to production changes and high efficiency significantly enhance production quality and worker safety.
Need automation solutions? Robot Store offers 6-axis and articulated robots for efficient manufacturing. Our inventory meets your assembly, packaging, and welding needs. Discover more about 6-axis robots now.
How They Work
Articulated robots adjust their joints to move the end-effector as required. Here’s how it works:
- Command Input: The robot gets instructions from a program, PLC, or operator through a teach pendant.
- Kinematics Calculation: The controller computes the angles for each joint using forward and inverse kinematics:
- Forward kinematics: Calculates the end-effector’s position based on joint angles.
- Inverse kinematics: Determines the joint angles necessary to reach a targeted position.
- Motion Control: Servo motors at each joint position the robot’s links accurately.
- Task Execution: The end-effector carries out tasks like welding, picking, or painting.
- Feedback and Adjustment: Sensors give real-time updates to maintain accuracy and safety.
Manual Labour vs. Articulated Robots – Cost & ROI Analysis
This is a simple cost and ROI comparison between manual labor and 6-axis industrial robots, presented in a way that a CFO or operations manager can easily assess. The prices are estimated based on integration levels and company size.
1) Cost Structure Comparison
Articulated Robots (6-axis)
Initial Costs (CapEx):
- Robot arm: £15k–£100k+
- Tooling & integration: £20k–£80k+
- Total system: £40k–£180k+
Operating Costs (OpEx):
- Energy and maintenance: ~£10k–£15k/year
- Electricity usually < 1k/year
- Hourly rate: ~£1.00–£2.00
Manual Labour
Upfront Costs:
- Hiring and onboarding: £700–£5k per worker
Ongoing Expenses:
- Salary: £25k–£40k+ annually (common UK range)
- Overtime, benefits, and turnover costs
- Losses in productivity (breaks, fatigue, absenteeism)
2) Cost per Unit & Productivity
Key Insight:
- Robots win when volume + repetition + consistency matter.
- Robots deliver 2×–10× output per cost in repetitive tasks
Example (50,000 parts/year):
- Robot: £0.32 per part
- Human: £0.64 per part (≈2× higher)
- Robots operate 24/7 without downtime, unlike shift-based labour
3) ROI & Payback Period
Typical ROI Benchmarks
Scenario
- High-volume manufacturing
- Payback period: 6–12 months
- General industrial automation payback: 1–3 years
- Conservative estimates payback: ~2 years
Example ROI Calculation
- Robot investment: ~$68k
- Labour savings: ~$140k/year
- Payback: ~6 months
After payback, robots save costs for around 15–20 years
4) Total Cost of Ownership (TCO)
6 Axis Robots
- Pros:
Lower lifetime cost
Predictable expenses
No overtime or shift premiums
Consistent performance - Cons:
High initial cost
Complex integration
Requires technical expertise
Manual Labour
- Pros:
Low initial cost
Flexible for varied tasks
No integration required - Cons:
Increasing wages
Training and turnover costs
Inconsistent performance
Limited growth potential
5) Strategic Value Beyond Cost
Tasks Best Suited for Robots
- High-volume, repetitive jobs (welding, pick & place)
- Continuous operations (24/7)
- Precision-focused production
- Addressing workforce shortages
Tasks Best Suited for Humans
- Low-volume / high-mix production
- Complex decision-making tasks
- Skilled manual work
- Quickly changing processes
6) Decision Framework (Simple Rule)
Choose articulated robots if:
- Labour cost exceeds £30k/year per operator
- Task is repetitive (over 70% cycle repeatability)
- Production requires 2 or more shifts
Consistent quality is essential
Opt for manual labour if:
- Volume is low or variable
- Tasks need judgment or flexibility
- CapEx budget is limited
Manual vs Robotic Automation: Cost Comparison for Manufacturing
Articulated robots require a higher initial investment than manual labor but have lower long-term costs. A human worker costs £30,000–£40,000 annually, while a robot incurs under £15,000 in energy and maintenance. Robots operate continuously, ensuring consistent quality and typically achieve payback in 6–24 months.
| Factor | 6-Axis Robot | Manual Labour |
|---|---|---|
| Initial Cost | £18,000 to £75,000+ | £25,000 to £70,000+ per worker /year |
| Operational Costs | Maintenance: £1,600 to £7,600/year | Wages: £25,000 to £70,000+ /year |
| Productivity | 24/7, high efficiency | Limited by hours and fatigue |
| ROI | 1-3 years | Rising costs over time |
| Safety | Lower risk, reduced insurance | Higher risk, increased premiums |
Upfront Investment
Articulated Robots
- Cost of robot units: £20,000 – £100,000+ per arm (varies by payload, reach, and precision)
- End-of-arm tooling (EOAT): £2,000 – £15,000+ (includes grippers, weld guns, vision systems)
- Safety and integration costs: £5,000 – £30,000+ (includes fencing, PLCs, software)
- Installation and commissioning: £5,000 – £40,000+
- Training and programming: £1,000 – £10,000+
- Total cost for automation setup: £40,000 – £180,000+ per work cell
Manual Labour
- Recruitment and onboarding: £500 – £3,000 per worker
- Workplace setup: minimal (PPE, tools), £200 – £2,000
- No integration costs for robots
- Total cost for a human worker: £700 – £5,000
Want to reduce labour costs and increase productivity?
Explore our range of articulated robots or request a custom ROI analysis for your application.
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Productivity & Throughput
Robots
- Operate continuously 24/7
- Consistent cycle times (no fatigue)
- High precision and reliability
- Can minimise defects
Humans
- Limited by shifts (8 – 12 hrs)
- Needs breaks, prone to fatigue, variable performance
- Higher error rates in repetitive tasks
- Robots usually provide 2× – 10× the output per cost compared to manual labour in repetitive, high-volume work.
Cost Per Part (Example)
Scenario: Pick & place task producing 50,000 parts/year
With Robot
- Capital cost spread over 5 years: £30,000 total → £6,000/year
- Operating cost: £10,000/year
- Total cost/year: £16,000 → £0.32 per part
With Manual Labour
- Worker cost/year: £32,000 → £0.64 per part
- Robot cost per part is about 50% of manual.
Buying Articulated Robots: Important Factors to Consider
6-Axis Robots have joints allowing movement in multiple directions. Each axis represents a degree of freedom (DOF), defining the robot’s movement capabilities. Here is an overview of the different types of robot axes:
Key Factors When Buying a 6-Axis Robot
When selecting a 6-axis articulated robot, consider these key factors:
- Payload Capacity – Choose a robot that can handle your tool and workpiece weight.
- Reach & Working Envelope – Ensure the robot’s arm length fits your workspace.
Speed & Cycle Time – Balance speed and precision for optimal productivity. - Precision & Repeatability – Essential for welding, painting, and quality control.
- Mounting Options – Floor, wall, ceiling, or gantry-mounted for space efficiency.
- Integration with Automation – Ensure compatibility with PLC, vision systems, and AI.
- Safety Features – Look for collision detection, speed limits, and ISO compliance.
- Programming & Ease of Use – User-friendly interfaces reduce setup time.
- Cost & ROI – Factor in initial investment, maintenance, and efficiency gains.
Best Choice: Select a robot that fits your payload, space, precision, and automation needs.
Example of Articulated Robots in Use
Consider a robotic welder on a car assembly line:
- Axes 1–3 move the welding torch into position near the car frame.
- Axes 4–6 adjust the torch angle to align with the seam.
- The torch performs the weld while all axes operate smoothly.
- Sensors monitor the weld quality and prevent collisions.
Types of Robot Axes
Robots are categorized by their axes (degrees of freedom), which influence their movement and suitability for various tasks:
- 1-Axis Robots – Perform simple linear motions (e.g., conveyors).
- 2-Axis Robots – Offer basic movement for simple pick-and-place tasks.
- 3-Axis (Cartesian) Robots – Capable of X, Y, Z movements for CNC and 3D printing.
- 4-Axis (SCARA) Robots – Fast and accurate, suitable for assembly and pick-and-place operations.
- 5-Axis Robots – Provide flexibility, often used in palletizing and packaging.
- 6-Axis Robots – Most versatile, enabling full 3D motion for welding, painting, and assembly.
- 7+ Axis Robots – Offer enhanced flexibility, ideal for human-robot collaboration.
Choosing the Right Robot for Your Needs
- 3-Axis: Best for CNC, 3D printing, and basic automation.
- 4-Axis: Suitable for high-speed pick-and-place and palletizing tasks.
- 6-Axis: Most versatile option for advanced industrial automation.
- 7+ Axis: Ideal for specialized tasks requiring high flexibility.
Which One Should You Choose?
- Choose 6-Axis → If you need flexibility, rotation, and multi-functional automation (welding, painting, palletizing).
- Choose SCARA → If you need speed and precision for repetitive tasks (assembly, pick-and-place).
- Choose Cartesian → If you need high accuracy and a fixed working area (CNC, material handling).
What Are Robotic Axes?
In industrial robots, axes (or degrees of freedom) denote the various movements a robot can perform. Each axis indicates a specific type of motion, like rotation or translation, allowing the robot to complete tasks in different directions.
How Robot Axes Work Together:
- More axes on a robot mean greater flexibility and precision in its movements.
- For instance, 6-axis robots use both linear and rotational axes to perform tasks like welding, painting, and assembly.
Key Benefits of Robotic Axes:
- More Flexibility – Extra axes allow for more directions and movement options for the robot.
- Accuracy – More axes mean better control and precision.
- Advanced Movements – Additional axes enable robots to carry out complex tasks, like welding and assembly.
Types of Robot Axes - Explained
- Linear Axes
- Translation (Straight-line Movement): Movement along X, Y, or Z axes.
- X-axis: Moves left to right (horizontal).
- Y-axis: Moves forward and backward (horizontal).
- Z-axis: Moves up and down (vertical).
- Rotational Axes
- Rotation around a fixed point: Movement around a specific axis.
- Yaw: Rotates around the vertical axis.
- Pitch: Rotates around the horizontal axis.
- Roll: Rotates around the front-to-back axis.
Example Robot Axes in Action
A 6-axis robot uses three axes (X, Y, Z) for positioning the arm and three axes (yaw, pitch, roll) for adjusting tool orientation. This setup enables it to perform tasks like welding in tight spaces.
Articulated Robots: Technical FAQs
What is an articulated robot?
The term “articulated” refers to the fact that the arm of the robot is made up of multiple “joints” or “articulations” that allow it to move flexibly, similar to the joints in a human arm. These robots typically have six degrees of freedom (DOF), enabling complex tasks in a 3D space.
What are the main components of an articulated robot?
The main components are:
- Manipulator/Arm: The structure consisting of multiple segments (links) connected by joints.
- Joints: Rotary or revolute joints that allow movement in one or more axes.
- End-Effector: The tool attached to the robot arm for performing tasks (e.g., grippers, welding torches).
- Controller: The computer system that commands the robot’s movements and processes feedback.
- Power Supply: Provides the necessary energy for the robot’s operation.
How do articulated robots differ from SCARA and Cartesian robots?
- Degrees of Freedom: Articulated robots generally have more DOF, allowing more complex movements.
- Structure: SCARA robots have two rotational and one linear axis, while Cartesian robots move linearly in three orthogonal axes.
- Applications: Articulated robots are used for more complex, 3D tasks, whereas SCARA and Cartesian robots are typically used for simpler, more planar operations.
What are the common applications of articulated robots?
- Manufacturing: Welding, painting, assembly, pick-and-place operations.
- Packaging and Palletizing: Sorting and organizing products.
- Inspection and Quality Control: Visual inspection and testing.
- Medical Applications: Surgical assistance, rehabilitation.
What are the advantages of using articulated robots?
The advantages are:
- Flexibility: High degree of freedom allows for complex movements and tasks.
- Precision: Accurate and repeatable operations.
- Versatility: Can be reprogrammed for different tasks.
- Efficiency: Increased productivity and consistency in tasks.
How are articulated robots programmed?
- Teach Pendant: A handheld device used to manually guide the robot through its tasks.
- Offline Programming: Using software to create and simulate robot tasks before uploading to the robot.
- Programming Languages: Proprietary languages or standard languages like Python, C++, or ROS (Robot Operating System).
What are the limitations of articulated robots?
- Cost: High initial investment.
- Complexity: Requires sophisticated programming and maintenance.
- Space: Needs a considerable amount of space for operation.
How can the performance of an articulated robot be optimized?
- Regular Maintenance: Routine checks and servicing to ensure smooth operation.
- Proper Training: Ensuring operators and programmers are well-trained.
- Up-to-date Software: Using the latest software for improved functionality and security.
- Optimized Workflows: Designing efficient workflows to minimize downtime and maximize productivity.
What factors should be considered when selecting an articulated robot?
- Payload Capacity: The weight the robot can handle.
- Reach: The distance the robot can extend its arm.
- Speed: The operational speed of the robot.
- Precision: The accuracy of the robot’s movements.
- Workspace: The volume within which the robot operates.
- Environment: Suitability for the working environment (e.g., cleanrooms, hazardous conditions).
What safety measures are necessary when working with articulated robots?
- Safety Fences and Barriers: Physical barriers to prevent human entry into the robot’s operational area.
- Emergency Stop Buttons: Accessible buttons to immediately halt robot operations.
- Sensors and Vision Systems: To detect human presence and prevent collisions.
- Compliance with Standards: Following international safety standards like ISO 10218 for robot safety.
Why Buy 6-Axis Robots?
6-axis robots are known for their flexibility, precision, and efficiency, making them suitable for various industrial tasks. With six degrees of freedom, they can perform complex movements, operate in tight spaces, and execute jobs such as welding, painting, palletizing, machine tending, and assembly.
Key benefits include:
- Versatility – Can adapt to many applications with simple reprogramming.
- Precision & Consistency – Maintains high accuracy for operations.
- Increased Productivity – Offers quicker cycle times and fewer errors.
- Space-Saving – Features a compact design with ample working range.
- Cost-Effective – Provides long-term savings on labor, waste, and upkeep.
- Seamless Integration – Works well with PLCs, vision systems, and AI.
- Enhanced Safety – Helps reduce workplace injuries and improve ergonomics.
Are you ready to purchase an 6-Axis robot?
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Advantages between new vs used industrial robots
Consider the pros of new and used industrial robots and choose according to your specific needs and circumstances. Here are some advantages of each:
Advantages of new six-axis robots:
Latest technology: New six-axis robots feature the latest technological advancements not found in older models.
Longer lifespan: They tend to last longer and require less maintenance over time.
Guarantee and support: New six-axis robots typically come with a warranty and technical support, ensuring assistance for any technical issues.
Customisation: These robots can be customized in terms of payload capacity, reach, and speed to meet specific needs.
Safety: New robots comply with the current safety standards and regulations.
Advantages of used 6-Axis robots:
Lower cost: Used robots are often much cheaper than new ones, which is appealing for budget-conscious companies.
Availability: Used robots are frequently available as they come from companies that are upgrading or downsizing.
Shorter lead times: Used robots may be delivered faster than new ones, which benefits companies with tight production schedules.
Familiarity: Used robots could be the same models as those already in operation, facilitating easier integration and operation.
Sustainability: Opting for a used robot is a more sustainable choice, helping to reduce waste from new robot manufacturing.
Choosing between new and used robots depends on the buyer’s needs. Evaluating costs and benefits can help in the decision process.
Robot Store specializes in industrial automation. We offer affordable used robots for sale, including ABB, KUKA, and Fanuc Robots.
What is involved in refurbishing an articulated robot?
Refurbishing articulated robots involves a step-by-step process to ensure they function as intended. This process includes inspecting, repairing, and upgrading the robot to meet the manufacturer’s specifications. Here are the key steps in refurbishing an industrial robot:
Inspection: Begin by checking the robot for signs of wear, damage, or other problems.
Cleaning: Thoroughly clean the robot to remove grease and dirt buildup.
Replacement of parts: Replace any damaged or worn parts with new or refurbished ones to restore functionality.
Upgrades: Improve the robot’s performance by upgrading components like the controller, adding new sensors, or enhancing the end-effector.
Testing: Conduct tests to confirm the robot operates reliably and meets original specifications.
Certification: After refurbishment, obtain certification from the manufacturer or a third party, confirming that the robot meets quality and safety standards.
Guarantee: The refurbished robot may include a warranty or service contract for ongoing support and reliability.
Refurbished industrial robots offer a cost-effective alternative to new robots, particularly for budget-conscious companies. It is crucial to partner with a reliable refurbisher who adheres to proper refurbishment protocols to ensure safety and reliability.
