Development of two identical automation cells with machining centers, integrated washing system and advanced quality control – designed for maximum autonomy and traceability.

Client Needs & Project Goals

A foundry client approached Iskra PRO with an ambitious project: to set up automated production cells with two machining centers that would process aluminium parts according to the highest standards of cleanliness, traceability, and product quality. Special focus was placed on robotized handling, advanced optical inspection and leak testing integration.

The client requested:

  • Fully automated process from raw part to packaging
  • Integrated industrial washing after machining
  • Reliable optical control for porosity and multi-layer detection
  • Leak testing with high precision
  • Full traceability of each individual part
  • Maximum autonomy with minimal operator involvement

“We needed flexibility and consistency — Iskra PRO delivered both. Their system helped us scale efficiently while improving quality at the same time.”

Technical Overview & Implementation Details

We designed and built two identical production cells with the following components and complete process includes:

    • 2x Brother CNC machining center
    • 2x Custom clamping fixture for accurate part positioning
    • 2x Robotic arm with external camera for part picking from the input conveyor
    • Washing unit for post-machining cleanliness
    • Vision system for quality control
    • Leak testing unit using four parallel setups
Automated Machining Cell

Key technical challenges

Our partner received:

  • Dynamic picking from a linear conveyor using a camera-guided robot
  • Robust vision system for diverse defect types
  • Parallelized leak testing for high throughput and reliability
  • Palletizing and blister handling with automated transport logic

In addition to technical design, we also considered:

  • Client-specific standards for part cleanliness and traceability (aligned with ISO)
  • Layout and spatial constraints within the client’s existing production hall

Step-by-Step Assembly Process

1. Visual-Guided Robotic Pick-Up

A robot equipped with a vision system identifies the exact position of parts on a conveyor. This ensures accurate pick-up, even if parts are slightly misaligned, setting the stage for a fully automated and reliable process.

2. CNC Machining

The robot feeds the parts into a CNC (Computer Numerical Control) machining center, where they are precisely processed according to design specifications. This step is critical for ensuring dimensional accuracy and meeting tight tolerances.

3. Robotic Transfer to Washing Unit

After machining, the robot moves each part into a specialized washing unit for cleanliness. Here, machining residues like oils and chips are removed, preparing the parts for inspection and further processing.

4. Optical Inspection

Once washed, each part undergoes a thorough optical inspection. Cameras and sensors check for porosity, surface imperfections, and multi-layer faults to ensure compliance with visual quality standards.

5. Leak Testing

Parts are automatically transferred to one of four leak testing chambers. Each part is tested for airtightness or fluid sealing, depending on the product’s function. Only parts that pass this critical step continue.

6. Automated Blister Packing

Approved parts are picked and placed by the robot into blister trays, ensuring safe and organized handling for transport. This step minimizes manual labor and contamination risk.

7. Palletizing for Shipment

When a blister tray is filled, a cartesian robot lifts and places it onto one of two Euro pallets. This completes the automated line, making the parts ready for final shipping with traceability and order management in place.

Key Results Achieved

  • Reduction in operator time vs. previous solution
  • Two independent cells, running in 3 shifts with minimal supervision
  • Enhanced traceability of each individual product
  • Production capacity increase within the same footprint

Client benefits

  • Fully automated workflow from raw part to pallet
  • Industrial washing for cleanliness compliance
  • Vision system for advanced quality inspection
  • High-precision leak testing with four parallel units
  • Automated blister handling and palletizing
  • Reduced defect rate, increased productivity
Automated Machining Cell 2
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Thomas Magnete

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