Robotic Programming Services: Industrial Robot Programming for ABB, FANUC & KUKA
Expert robotic programming for UK manufacturers. Our engineers program new and used ABB, FANUC and KUKA robots on-site, remotely or offline in simulation: new robot programs, cycle-time optimisation, reprogramming for new parts, fault finding and commissioning. Remote robot programming from £75/hr and on-site programmers from £600 a day.
Remote robot programming and support
Day rate for an on-site robot programmer
ABB RAPID, FANUC TP/KAREL and KUKA KRL
Reply with a scope and price
Robotic programming: what it is and what we do
Robotic programming (also called robot programming) is writing the instructions that tell an industrial robot where to move, how fast, and what to do at each point: grip, weld, spray, place or wait for a signal. A robot program combines taught or simulated positions, motion commands, I/O signals to the tooling and PLC, and process logic, written in the robot maker’s language such as ABB RAPID, FANUC TP or KUKA KRL.
Most of the savings from a robot come from how well it is programmed, not from the robot itself. A well-programmed robot runs a shorter cycle, recovers from faults on its own and is easy for your operators to change over. Our engineers write robot programs for new cells, take over and improve existing programs, and reprogram used robots for new parts and new jobs, on any of the robots we sell or the ones already on your shop floor.
Our robotic programming services
Choose the way of working that suits your job and your production. Most projects use a mix: we develop the program offline, commission it on-site, then support it remotely.
Remote robot programming
Program changes, troubleshooting and optimisation over a secure remote connection to your robot controller or PC, with no travel cost.
- Program edits, new points and part offsets
- Alarm and fault diagnosis
- Backups, restores and software checks
- Out-of-hours support by arrangement
From £75/hr
On-site robot programming
An experienced robot programmer at your site to commission, tune and fault-find, and to get the cell into production.
- Commissioning and production ramp-up
- Touch-ups, TCP and frame calibration
- Cycle time and path tuning on the real cell
- Operator handover at the robot
From £600/day
Custom robot programming
Complete bespoke robot programs for a new cell or a new product, from the sequence design to error recovery and the operator screens.
- Full program structure and logic
- Robot-to-PLC handshake and I/O mapping
- Error handling and safe recovery
- Documentation and program backups
From £2,500
Offline robot programming (OLP)
Robot programs built and tested in RobotStudio, ROBOGUIDE or KUKA.Sim before they reach the robot, so production keeps running.
- Reach and cycle time checks
- Collision-free paths from your CAD
- Welding, milling and complex paths
- Faster commissioning on site
From £1,200
More robot programming work we do
Cycle time optimisation
Faster paths, better blending zones and fewer fine points. Even 0.5 s off a cycle pays back quickly in high-volume production.
Robot reprogramming
New parts, new grippers, a moved fixture or a used robot for a new job. We update or rewrite the program and re-teach the points.
Multi-robot coordination
Interlocks, shared zones and synchronised motion for cells with two or more robots, tracks and positioners.
Vision and sensor programming
Camera-guided picking, part location and inspection, seam tracking and force sensing, set up in the robot program.
Robot to PLC communication
Signals and handshakes over PROFINET, EtherNet/IP or PROFIBUS between the robot and your line PLC. Full PLC and control design is on our robot control page.
Backups and program recovery
Full controller backups, lost or corrupted programs restored, and taking over programs left by another integrator.
How much does robot programming cost?
Robot programming costs £75 to £110 an hour remotely, or £600 to £900 a day for an on-site robot programmer in the UK. Offline robot programming projects start from £1,200 and complete custom programs for a new robot cell from £2,500. A small change to an existing program often takes one to three hours, while a new single-robot program usually takes one to five days, depending on the application.
| Programming service | Typical price (ex VAT) | What is included | Best for |
|---|---|---|---|
| Remote robot programming | £75 – £110/hr | Program edits, fault finding, optimisation and backups over a secure connection | Small changes, alarms, quick support |
| On-site robot programming | £600 – £900/day | Engineer at your site for commissioning, touch-ups, TCP/frame calibration and tuning (travel quoted separately) | Commissioning, ramp-up, hands-on fault finding |
| Offline robot programming (OLP) | From £1,200 | Simulation in RobotStudio, ROBOGUIDE or KUKA.Sim, reach and cycle time study, collision-free paths, program export | Complex paths, new parts, avoiding downtime |
| Custom robot programming | From £2,500 | Full program structure, process logic, PLC handshake, error recovery, documentation | New robot cells and new products |
| Small program change | 1 – 3 hours | New points, part offsets, speed changes or a new I/O signal | Quick tweaks (billed at the remote rate) |
| New pick-and-place or tending program | 1 – 3 days | Single robot, one product, gripper and PLC signals | Machine tending, packing, handling |
| New welding or palletising program | 1 – 5 days | Weld paths and parameters, or pallet patterns and layer logic | Weld cells and end-of-line palletising |
Prices are estimates and depend on the robot brand, the application, the state of the existing program, travel and how much is done offline. Looking for the price of a robot rather than programming? See robot prices. For a complete cell with guarding, safety and CE marking see robotic integration.
What affects the cost of robot programming?
Application complexity
A simple pick-and-place takes far less time than multi-pass welding, 5-axis milling or a mixed-product palletising pattern.
Starting point
Writing from scratch costs more than editing a clean, documented program. Undocumented programs from another integrator take longer to take over.
CAD and offline work
With good CAD files (STEP or IGES) most of the work is done offline, which shortens the expensive on-site time.
Integration and signals
Each extra device (PLC, vision, welder, safety system, conveyor) adds signals, logic and testing time.
Offline robot programming (OLP): RobotStudio, ROBOGUIDE & KUKA.Sim
Offline robot programming means writing and testing the robot program on a PC, in a 3D simulation of your cell, instead of on the real robot. The finished program is then loaded into the controller and touched up on site. Your robot keeps producing while the new program is written.
We use each maker’s own software, so the simulated robot runs the same controller software as the real one: ABB RobotStudio (virtual IRC5 and OmniCore controllers), FANUC ROBOGUIDE (HandlingPRO, WeldPRO, PaintPRO) and KUKA.Sim with WorkVisual. For milling, trimming and complex welding we generate paths straight from your CAD model.
- Program new parts without stopping production
- Check reach, joint limits and singularities before you buy or move a robot
- Collision-free paths and cycle time proven in simulation
- Shorter commissioning: on-site work drops to touch-ups
- Thousands of accurate path points for milling, deburring and sealing
Offline vs online (teach pendant) robot programming
| Offline programming (OLP) | Online / teach pendant programming | |
|---|---|---|
| Production downtime | Little or none: written on a PC | Robot stops while it is programmed |
| Best for | Complex paths, welding, milling, new cells, many part variants | Simple moves, small edits, final touch-ups |
| Accuracy | Depends on accurate CAD and calibrated TCP and frames; touch-ups on site | What you teach is what you get |
| What you need | CAD of the parts and cell (STEP/IGES), simulation licence | Access to the robot and a trained programmer |
| Cost | Higher up front, lower total on complex jobs | Lower for small changes, higher in lost production |
Want a simulation of a whole new cell, with guarding, conveyors and layout? That is part of our robotic integration service. Want to learn RobotStudio or ROBOGUIDE yourself? See our robot programming courses.
Robot programming software compared
The right software depends on the robot brand and the job. Maker software runs a virtual copy of the real controller, so cycle times and reach are accurate; multi-brand tools are best for CAD-heavy paths across mixed fleets. We use all of these, so you don’t need to buy a licence to get an offline program.
| Software | Robots | Best for | Licence |
|---|---|---|---|
| ABB RobotStudio | ABB (IRC5, OmniCore) | Virtual controller, RAPID editing, cell layout, machining paths | Basic features free; full simulation is paid |
| FANUC ROBOGUIDE | FANUC (R-30iA, R-30iB) | HandlingPRO, WeldPRO, PalletPRO and PaintPRO cells, TP program testing | Paid licence per package |
| KUKA.Sim / WorkVisual | KUKA (KRC4, KRC5) | Layout and reach studies, KRL testing; WorkVisual for configuration | KUKA.Sim paid; WorkVisual free |
| RoboDK | Most brands | Multi-brand offline programming, CAD-to-path, milling and 3D printing | Paid, with a free trial |
| Robotmaster | Most brands | Complex CAM-based paths: trimming, deburring, welding, polishing | Paid |
| URSim / PolyScope | Universal Robots | Cobot programs and URScript testing | Free |
Want your team to use this software? See our RobotStudio and ROBOGUIDE training. Want us to do it? Ask for an offline programming quote.
ABB, FANUC & KUKA robot programming
Every robot maker has its own language, controller and software, so a programmer who knows one brand cannot simply pick up another. Our engineers program all three of the most common industrial robot brands in the UK, on current and older controllers, including the used robots we sell.
ABB robot programming
RAPID programs on IRC5, OmniCore and older S4C+ controllers, developed and tested in RobotStudio.
- RAPID modules, routines and work objects
- IRC5, OmniCore and S4C+ controllers
- SafeMove safety configuration
- ArcWare, PickMaster and palletising
FANUC robot programming
Teach pendant (TP) programs and KAREL for advanced logic on R-J3iB, R-30iA and R-30iB controllers.
- TP programs, macros and KAREL
- R-J3iB, R-30iA and R-30iB / Plus
- DCS safety and iRVision setup
- ArcTool, SpotTool, HandlingTool, PalletTool
KUKA robot programming
KRL programs on KRC2, KRC4 and KRC5 controllers, with WorkVisual for configuration and KUKA.Sim offline.
- KRL programs and inline forms
- KRC2, KRC4 and KRC5 controllers
- SafeOperation and PROFINET setup
- ArcTech, PalletTech and KUKA.CNC
Robot programming languages by brand
| Robot brand | Programming language | Controllers | Offline programming software |
|---|---|---|---|
| ABB | RAPID | S4C+, IRC5, OmniCore | RobotStudio |
| FANUC | TP (teach pendant) and KAREL | R-J3iB, R-30iA (R-J3iC), R-30iB / R-30iB Plus | ROBOGUIDE |
| KUKA | KRL (KUKA Robot Language) | KRC2, KRC4, KRC5 | KUKA.Sim, WorkVisual |
| Yaskawa Motoman | INFORM | DX100, DX200, YRC1000 | MotoSim |
| Kawasaki | AS language | E and F controllers | K-ROSET |
| Universal Robots (cobots) | URScript and PolyScope | CB3, e-Series | URSim |
| Multi-brand | Generated from CAD | Any of the above | RoboDK, Robotmaster |
The core steps are the same on every brand: teach or generate positions, program the motion, set up the I/O, add the logic and test. We program ABB, FANUC and KUKA robots every week; ask us about other brands.
Robot programming methods: which one is right?
There are five main ways of programming robots. Which one is best depends on the robot type, the application, how often the job changes and the skills of your team. Most industrial cells use a mix: offline programming for the paths, the teach pendant for touch-ups and text-based code for the logic.
| Method | How it works | Best for | Limits |
|---|---|---|---|
| 1. Teach pendant programming | Jog the robot with the handheld pendant and record each point | Simple moves, touch-ups, small edits | Robot stops while you program; slow for complex paths |
| 2. Offline programming (OLP) | Program and test in 3D simulation, then load into the robot | Welding, milling, new cells, many variants | Needs accurate CAD and calibration |
| 3. Text-based programming | Write code in RAPID, KRL, KAREL and similar languages | Logic, communication, recipes, error handling | Needs skilled programmers |
| 4. Lead-through (hand guiding) | Move a cobot by hand while it records the path | Cobots, quick simple tasks | Limited precision and logic |
| 5. Graphical / no-code | Drag-and-drop blocks or wizards on a tablet | Simple cobot jobs, beginners | Limited for advanced logic |
How to program a robot using the teach pendant
A teach pendant is the handheld unit used to move an industrial robot, record positions and write programs. The buttons and screens differ between the ABB FlexPendant, the FANUC iPendant and the KUKA smartPAD, but how to program a robot is the same on all of them: teach the points, add motion and I/O, then test safely. Here are the eight steps our engineers follow.
Power up and select teach mode
Switch the controller to manual (T1) mode, check the emergency stops and enabling device work, and make sure nobody else is in the cell.
Set the tool and frames
Select or measure the tool (TCP) and the base or user frame you will teach in, so every point is recorded relative to the right reference.
Jog the robot
Move the robot axis by axis (joint) or in straight lines (world, tool or user frame) with the pendant keys or joystick.
Record the positions
Save each position as a point. Use clear names such as pPick or P[10:Above_Fixture] so the program is easy to edit later.
Add motion commands
Insert joint, linear or circular moves and choose the speed and the blending zone (fine or continuous) for each one.
Set up the I/O signals
Add outputs to open and close the gripper, start the welder or signal the PLC, and wait for inputs such as part present.
Add the process logic
Use IF statements, loops, registers or variables, timers and subroutines to handle part variants, counts and errors.
Test, then run in automatic
Step through the program at low speed, check for collisions, raise the speed, then switch to automatic and check the cycle time.
Best practice for teach pendant programming
- Follow lockout and machine safety procedures every time
- Check the TCP and frames before recording any points
- Use joint moves in tight spaces and linear moves near the part
- Avoid unnecessary moves and fine points to keep the cycle short
- Name programs, points and variables clearly and add comments
- Test at reduced speed first, then increase it when safe
- Back up the controller before and after every change
- Record every program change for maintenance
Common robot programming mistakes
- Wrong tool or frame selected, so points drift or the robot misses
- Unexpected wrist flips caused by the wrong configuration data
- Too many fine points, making the motion jerky and slow
- Programs that wait forever because an input is mapped wrongly
- No safe home position or recovery routine after a stop
- Changes made on the robot but not copied back to the offline model
Want your own team to do this? Our robot programming courses cover ABB, FANUC and KUKA teach pendant programming, hands-on.
Why coordinate systems matter in robot programming
A coordinate system works like a map for the robot. Every point in a program is stored relative to one, so “move 50 mm along X” means something different in each frame. The base frame is where the robot stands, the tool frame (TCP) is the working tip of the gripper or torch, and the work frame (ABB work object, FANUC user frame, KUKA base) is where the part or fixture sits.
- Accurate positioning: the robot hits each point exactly
- Quick re-teaching: move a fixture, re-teach 3 points of its frame and the whole program follows
- Offline programs that work: simulated paths match the real robot when frames are calibrated
- Multi-robot cells: shared frames let robots, tracks and positioners work together
- Fewer collisions: paths behave as expected after a reset or a tool change
Robot programming for every application
Each application needs its own programming know-how, process packages and checks. These are the jobs we program most often.
| Application | What we program | Software / options | More about the application |
|---|---|---|---|
| Arc and spot welding | Weld paths, weave, seam tracking, torch cleaning, weld schedules | ArcWare, ArcTool, ArcTech, SpotTool | Welding robots |
| Palletising | Pallet patterns, layer sheets, mixed SKUs, pallet change logic | PalletTool, PalletTech, PickMaster | Palletising robots |
| Machine tending | CNC and press loading, door and chuck signals, part counting | HandlingTool, PROFINET/EtherNet/IP | Manufacturing robots |
| Pick and place and packing | Vision picking, conveyor tracking, high-speed moves | iRVision, PickMaster, conveyor tracking | Types of robots |
| Painting and coating | Spray paths, gun triggers, colour changes | PaintPRO, RobotWare Paint | Robotic painting |
| Milling, trimming and deburring | CAD-to-path programs with thousands of points, feed and spindle control | RobotStudio Machining, KUKA.CNC, Robotmaster | Milling robots |
| Assembly | Insertion, screwing, force control, error recovery | Force control, vision | Robotic assembly |
| Dispensing and sealing | Constant-speed glue and sealant paths, flow control | Dispense packages, offline paths | Ask us |
How good robot programming cuts manufacturing costs
A badly programmed robot costs money every shift. A well-programmed one pays back quickly. These are the savings our customers see after we program or optimise their robots.
Shorter cycle times
Optimised paths, speeds and blending. 0.5 s saved on a 30 s cycle adds about 1.7% more parts per shift.
Less scrap and rework
Repeatable, accurate paths give consistent welds, beads and placements.
Less downtime
Error handling and recovery routines get the cell running again without an engineer.
Lower maintenance
Smooth motion means less shock on reducers, cables and tooling.
Lower energy use
Correct acceleration and fewer wasted moves, especially in multi-robot cells.
Faster changeovers
Structured programs and recipes let operators switch products in minutes.
From our integrators: most of the savings from a robot come from the programming and integration, not the purchase price. A robot that is not programmed properly costs a lot; a properly programmed robot pays for itself quickly.
How to find robot programming errors
Most robot program problems fall into a few groups. Before you rewrite a program, check these in order. When the logic looks right but the motion is wrong, the cause is usually the TCP, a frame or the configuration data, not the program itself.
- Check positioning accuracyPoints missed or paths offset? Verify the tool data (TCP), payload and work frames first.
- Watch for posture changesSudden wrist flips or elbow jumps point to wrong configuration data or the wrong motion type.
- Read the alarm messageController alarms name the logic, syntax, motion or signal problem. Note the exact code and text.
- Check speeds and zonesHesitation or jerky motion usually means wrong speeds, too many fine points or small blending zones.
- Monitor I/O and conditionsA program that waits forever or skips a step has a wrongly mapped signal or an unmet condition.
- Compare simulation and robotDifferences suggest calibration, tool or base data, or mechanical changes not in the model.
Robot down now?
Send us the robot model, controller and the alarm text. Our engineers can often connect remotely and find the fault the same day. For hardware faults and parts see FANUC spares, ABB parts or KUKA Parts.
Our robot programming process
Brief and survey
You send the robot model, controller, application, cycle target and CAD files. We review the existing programs and backups if there are any.
Simulation and offline program
We build the cell in RobotStudio, ROBOGUIDE or KUKA.Sim, check reach and cycle time and write the program offline.
Programming and testing
Logic, I/O, PLC handshake and error recovery are added and tested in simulation, then loaded into your robot.
On-site commissioning
An engineer touches up the points, calibrates the TCP and frames, tunes the cycle and runs production with your team.
Handover and support
You get full backups, documentation and an operator walkthrough, plus remote support whenever you need changes.
Why choose us for robotic programming?
Multi-brand robot programmers
ABB, FANUC and KUKA engineers in one team, on current and older controllers, so one supplier covers a mixed shop floor.
Integrators, not just coders
We build and integrate robot cells, so our programs handle the PLC, safety, tooling and the people who run the cell.
Offline first
Most of the work is done in simulation, which keeps your downtime and our on-site days to a minimum.
We know used robots
We refurbish and sell used robots, so we can program older controllers that many integrators no longer support.
Documented and backed up
Every job ends with clear comments, a full backup and notes, so any engineer can maintain the program later.
Support after go-live
Remote support for changes, new parts and faults for as long as you run the robot.
Industries we program robots for
- Automotive and electric vehicles
- Aerospace and defence
- Metal fabrication and welding
- Packaging, food and logistics
- Painting and surface coating
- Plastics and machine tending
- General manufacturing
Hire a robot programmer or train your own team?
Manufacturers often wonder if they should outsource robot programming, hire a robot programmer, or train their own staff. Most choose a combination: using a specialist for new programs and major changes, while having trained operators handle daily adjustments. We can assist you, whether in the UK or globally.
| Outsourced robot programmer (us) | Employ a robot programmer | Train your own staff | |
|---|---|---|---|
| Best for | New programs, new cells, OLP, optimisation, breakdowns | Large sites with many robots and constant changes | Touch-ups, restarts, small edits, recovery |
| Cost | Pay per job: £75/hr remote, £600–£900/day on-site | Full-time salary, plus software and training | Course fees and time off the line |
| Brands covered | ABB, FANUC and KUKA in one team | Usually one or two brands | The brands you run |
| Speed to start | Days, or same day for remote support | Months to recruit | A few days of training |
| Software licences | Included | You buy them | You buy them for offline work |
Get a robot programming quote
Tell us about your robot and the job. An engineer replies the same working day with a scope, the number of hours or days and a price. Send CAD files or a program backup and we can quote more accurately, and often do more of the work offline.
- A fixed or estimated priceHours or days, rates and travel, ex VAT
- The best way to do itRemote, on-site, offline or a mix
- A simulation where it helpsReach and cycle time checked before we start
- Start datesIncluding urgent breakdown support
Prefer email? Write to info@robot-store.co.uk
Robotic programming: frequently asked questions
What is robotic programming?
Robotic programming is creating the instructions that tell an industrial robot how to move and what to do: the positions, motion types and speeds, the I/O signals to its tooling and PLC, and the process logic. It is done on the teach pendant, offline in simulation software, or by writing code in the robot’s own language.
How much does robot programming cost in the UK?
Remote robot programming costs about £75 to £110 an hour and an on-site robot programmer £600 to £900 a day, plus travel. Offline robot programming projects start from £1,200 and custom programs for a new cell from £2,500 (ex VAT). See the robot programming cost table.
How long does it take to program an industrial robot?
A small change takes one to three hours. A new pick-and-place or machine tending program usually takes one to three days, and a welding or palletising program one to five days. A full multi-robot cell can take several weeks, much of it offline before commissioning.
What programming language do industrial robots use?
Each brand has its own: ABB uses RAPID, FANUC uses TP (teach pendant) programs and KAREL, KUKA uses KRL, Yaskawa uses INFORM, Kawasaki uses AS and Universal Robots uses URScript. See robot programming languages by brand.
What is offline robot programming?
Offline robot programming (OLP) is writing and testing robot programs in a 3D simulation, such as ABB RobotStudio, FANUC ROBOGUIDE or KUKA.Sim, instead of on the real robot. The program is then loaded and touched up on site, so the robot keeps producing while it is written. See offline programming.
What software is used to program industrial robots?
Each maker has its own offline programming software: ABB RobotStudio, FANUC ROBOGUIDE and KUKA.Sim, with WorkVisual for KUKA configuration. Multi-brand tools such as RoboDK and Robotmaster generate programs for most brands from CAD. See robot programming software compared.
Is offline programming better than teach pendant programming?
For complex paths, welding, milling, new cells and many part variants, yes: it saves downtime and proves the cycle first. For simple moves and small edits the teach pendant is quicker. Most cells use both: offline for the program, the pendant for final touch-ups.
Can you program my robot remotely?
Yes, if the controller or a PC on the robot network can be reached over a secure remote connection that your IT team approves. We make program changes, diagnose alarms and check backups remotely. Someone trained must be at the robot whenever it moves.
Can you reprogram a used or second-hand robot?
Yes. We reprogram used robots for new parts and new jobs every week, including the robots we sell. Older controllers such as ABB S4C+, FANUC R-J3iB and KUKA KRC2 are supported. Browse used robots for sale.
Can you take over a program written by another integrator?
Yes. We back up the controller, review and document the existing program, then fix, extend or rewrite it. Undocumented programs take longer, so send a backup with your enquiry and we will quote the time.
Do you need CAD files to program a robot offline?
For accurate offline programming, yes: 3D models of the part, fixtures and tooling, ideally in STEP or IGES format. Without CAD we can still simulate reach and layout with simple models, then teach the final points on site.
Can you reduce my robot's cycle time?
Usually, yes. We look at the path, speeds, blending zones, wait times and the handshake with the PLC and other machines. Even half a second saved per cycle adds up quickly in high-volume production.
Is robot programming hard to learn?
Basic teach pendant programming can be learnt in a few days; writing robust programs with logic, I/O and error recovery takes much longer. Our robot programming courses train your operators and engineers on ABB, FANUC and KUKA robots.
Can industrial robots be programmed with Python?
Not directly: production programs run in the robot’s own language (RAPID, KRL, TP/KAREL). Python is used alongside them, for example to generate paths, talk to the controller over its PC interface or ROS-Industrial drivers, or to run vision and data systems.
Do you program cobots?
Yes, including FANUC CRX, ABB GoFa and YuMi, KUKA LBR iiwa and Universal Robots cobots, using hand guiding, the tablet interface or code. A cobot application still needs a risk assessment before use.
What do you need from me for a quote?
The robot brand, model and controller, what the robot should do, the cycle time target, how many part variants there are, any CAD files or program backups, and your deadline. Use the quote form.
Will I get a backup and documentation?
Yes. Every job ends with a full controller backup, commented programs, a list of the I/O signals and a short operator walkthrough, so your team or any engineer can maintain the program later.
Need a robot programmed?
Send us the robot and the job. We’ll tell you the best way to program it, how long it takes and what it costs, today.
