Avalon Robotics’ innovative concept for preplating webs in open web floor trusses. This overview delves into the proven preplating process, offering insights into how it enhances efficiency and streamlines truss manufacturing. Learn about the steps, benefits, and potential applications of this automation concept, designed to optimize workflows and revolutionize the construction industry.

The Door Frame Assembly Cell is a robotic system designed to streamline and automate the assembly of interior door trim, specifically for mounting the inside trim pieces against which the door closes in the frame. This cell precisely positions and secures the trim components onto the door frame, ensuring accurate alignment and consistency across assemblies. Equipped with a router, the system efficiently cuts and finishes door striker holes to meet specified measurements and alignment, readying the door for secure locking and optimal functionality.

After completing each door frame assembly, the robotic cell automatically transfers the finished product to a dedicated stacking area, where it carefully places each frame on a transport cart. This stacking mechanism is engineered for stability and easy cart removal, minimizing downtime and expediting transportation to the next production stage. The Door Frame Assembly Cell is designed to boost productivity, quality, and safety by eliminating manual handling, reducing potential errors, and ensuring consistent, precise construction in each assembled door frame.

The Avalon Robotics Door Picking System is an intelligent robotic solution designed to select and organize doors directly from storage racks, enhancing operational efficiency and flexibility. This system identifies, selects, and arranges doors according to the specific sequence required for production or installation.
With advanced recognition and handling technology, the Door Picking System carefully lifts and organizes doors into a precise order, ready for the next stages of production. By streamlining the picking and stacking process, it ensures that doors are accessible in the correct order, reducing production delays and improving workflow. This automation minimizes manual handling, lowers the risk of door damage, and supports a more organized and efficient manufacturing environment.

The Avalon Robotics Door Trim Assembly System is an advanced robotic solution designed to receive framed doors from a KVAL system and seamlessly automate the trim application process. Upon receiving the framed door, the system carefully picks and places pre-cut trim pieces along the frame, ensuring accurate alignment to meet strict quality standards.
Using precision sensors, the Door Trim Assembly System performs a fine alignment to guarantee each trim piece is positioned correctly. Once aligned, the system securely nails the trim to the door frame with high accuracy, achieving a consistent, professional finish. By automating the trim installation, this system reduces manual labor, increases throughput, and maintains high levels of consistency across every door produced, making it an essential asset for efficient and quality-focused door manufacturing environments.

The Avalon Robotics Door Trim Assembly System is an advanced robotic solution designed to receive framed doors from a KVAL system and seamlessly automate the trim application process. Upon receiving the framed door, the system carefully picks and places pre-cut trim pieces along the frame, ensuring accurate alignment to meet strict quality standards.
Using precision sensors, the Door Trim Assembly System performs a fine alignment to guarantee each trim piece is positioned correctly. Once aligned, the system securely nails the trim to the door frame with high accuracy, achieving a consistent, professional finish. By automating the trim installation, this system reduces manual labor, increases throughput, and maintains high levels of consistency across every door produced, making it an essential asset for efficient and quality-focused door manufacturing environments.

The roof member preplate system is a highly efficient, containerized solution for precision nail plate placement in truss manufacturing. Housed within a 40-foot container, this automated system is designed for quick setup in a manufacturing facility. Equipped with robotic arms that pick nail plates from organized bins, the system accurately places and attaches each plate on roof members according to exact specifications. This precision in placement allows for smaller, appropriately sized nail plates to be used, reducing overall steel usage and lowering material costs without compromising structural integrity.

Once the members are preplated, they are batched together according to each truss before being delivered to the assembly tables. This ensures that all necessary components for a specific truss arrive together, streamlining the assembly process and reducing handling time for operators. By organizing components in advance, the system enhances production flow and efficiency, setting a new standard in component fabrication for truss manufacturing.

In this advanced setup, the delivery conveyors for preplated roof members are positioned exclusively above the outfeed rollers, creating an efficient, streamlined workflow. This configuration provides a clear, uninterrupted path for completed trusses to be slid onto the outfeed rollers while new, preplated members are delivered directly to the assembly tables. By utilizing only the space above the outfeed rollers, the system maximizes floor space, reducing congestion around the assembly area and freeing up valuable space within the facility.

This overhead delivery solution not only improves workflow efficiency but also enhances safety by maintaining organized pathways around the tables. The clear division of incoming and outgoing material flows allows operators to work faster and more effectively, enabling a continuous and efficient cycle of truss production without compromising workspace.

The roof member preplate system is a highly efficient, containerized solution for precision nail plate placement in truss manufacturing. Housed within a 40-foot container, this automated system is designed for quick setup in a manufacturing facility. Equipped with robotic arms that pick nail plates from organized bins, the system accurately places and attaches each plate on roof members according to exact specifications. This precision in placement allows for smaller, appropriately sized nail plates to be used, reducing overall steel usage and lowering material costs without compromising structural integrity.

Once the members are preplated, they are batched together according to each truss before being delivered to the assembly tables. This ensures that all necessary components for a specific truss arrive together, streamlining the assembly process and reducing handling time for operators. By organizing components in advance, the system enhances production flow and efficiency, setting a new standard in component fabrication for truss manufacturing.

The single robotic panel system is a fast and versatile solution designed for efficient panel production in either wood or cold-formed steel (CFS) construction. Engineered for speed, it can be set up to handle one material type at a time, allowing it to efficiently complete batches of panels in either wood or CFS. Once a batch of one material is completed, the system can quickly switch over to the other material type, making it ideal for manufacturers who need flexibility in production without sacrificing pace.

This streamlined system assembles panel frameworks with precision, using advanced automation to place studs and fasteners accurately. After each panel is framed, window and door openings are added manually, enabling easy customization as needed. Built to optimize throughput, this system is perfect for high-speed, batch-oriented production while delivering reliable quality across both wood and steel construction projects.

This onsite wall panel system revolutionizes residential framing by using robotics to assemble wall panels directly at the construction site. The system arrives in three 40-foot containers, delivered by semis and set up on the ground, creating a compact, efficient onsite factory. By building panels on location, this system eliminates the high costs and logistical challenges of transporting bulky, pre-fabricated wall panels from an offsite facility.

Once set up, a single operator controls the automated assembly process, guiding the robots as they cut, position, and fasten each panel with precision. This streamlined setup improves the quality and consistency of each wall panel, reducing errors and rework. As panels are completed, they are quickly moved to their installation points using a telehandler, which allows for smooth, efficient delivery within the site. This innovative approach not only accelerates the framing process but also provides significant cost savings and ensures high-quality framing tailored precisely to each build, redefining speed and efficiency in residential construction.

This two-story modular manufacturing facility maximizes vertical space, providing a compact yet highly efficient environment for producing fully automated walls, floors, and ceilings for modular construction projects. With automated systems and robotics strategically arranged across both floors, this facility minimizes its footprint, making it an ideal solution for densely populated urban areas where space is at a premium.

The upper level houses specific assembly stations and storage solutions, while the ground floor focuses on production flow, handling, and staging. Materials and components move seamlessly between floors via automated lifts, ensuring uninterrupted workflow and reducing manual handling. By centralizing operations in a vertical design, the facility allows workers to enjoy a consistent, single location, reducing commute times and boosting job satisfaction. This two-story setup not only enhances inventory and production management but also demonstrates a modern, efficient approach to urban manufacturing, perfectly suited for cities with limited space but high construction demand.

This one-story modular manufacturing facility is a streamlined, centralized hub dedicated to the efficient production of fully automated walls, floors, and ceilings for modular construction. Inside, advanced robotics and automation systems handle assembly, ensuring high-quality precision and consistency across every component. By consolidating operations in a single location, this facility allows workers to benefit from a stable work environment, eliminating the need to move between job sites daily.

Beyond improved workforce satisfaction, this setup enhances inventory management, with materials consistently stocked and monitored on-site, reducing delays. Production management and planning are optimized through integrated systems that track workflow, predict needs, and ensure seamless operation from start to finish. This facility stands as a comprehensive solution to modular construction, balancing automation with a consistent workspace to drive productivity, quality, and worker satisfaction.

The mobile rebar tying system is a cutting-edge, containerized solution designed to streamline the construction of rebar cages directly on-site. Upon delivery in a standard container, this robust system is delivered onsite for operation, providing a self-contained, automated assembly line for tying rebar members with precision. It utilizes advanced robotic arms and sensors to accurately tie rebar intersections, eliminating manual tying, which significantly reduces worker strain and the risk of injury. With its efficient workflow and high-speed processing, this mobile system enhances construction site safety and productivity, allowing for faster cage assembly and enabling workers to focus on higher-value tasks. The result is a seamlessly integrated, safer, and more efficient process for rebar cage fabrication that reduces downtime and improves overall site safety.

In this video, watch a state-of-the-art cable robot in action as it effortlessly picks and organizes trusses, placing them neatly into stacks. Our innovative Truss Stacker system is designed for optimal efficiency, enabling precise handling and sorting of trusses to build multiple stacks seamlessly. This powerful technology maximizes workflow by reducing manual handling and enhancing safety, making the truss stacking process faster and more reliable than ever. Experience the future of construction automation and see how our cable robot is setting new standards in productivity and organization on the job site.

In this demonstration video, a real robot is equipped with a specialized rebar tying gun to precisely secure rebar joints, showcasing the feasibility of automating this traditionally manual task. The robot, programmed for accurate, consistent movement, positions the tying gun at each rebar intersection and performs a secure tie with precision, ensuring optimal stability and alignment of the rebar structure. This demonstration highlights the potential for automated rebar tying to improve safety, speed, and consistency on construction sites, proving that robots can reliably handle rebar assembly with minimal human intervention. This prototype setup serves as a foundational step towards integrating robotic solutions for rebar tying, illustrating how automation can streamline labor-intensive processes in construction.

Installed at a large home improvement retailer, this advanced lumber-picking system brings a new level of convenience and safety to the shopping experience. Using a robotic arm on a guided track, the system efficiently manages and picks lumber stored in a multi-layered racking structure. The racks are designed to hold different sizes and types of lumber—like 2x4x10s and 4x4x6s—on two primary picking layers, with a third layer dedicated to additional storage.

A customer simply selects their desired lumber type and quantity through a digital interface, for example, 10 pieces of 2x4x10 and 2 pieces of 2x12x12. Once selected, they can continue shopping while the system automatically calculates the optimal picking order to ensure a safe, balanced stack. The robot retrieves the requested items, organizes them, and sends the assembled stack through an automatic banding machine, securely preparing the order for pickup.

By the time the customer is ready to leave, their lumber is bundled and ready for easy pickup—eliminating the need for heavy lifting and reducing the risk of injury. This innovative installation at a home improvement retailer enhances shopper safety, saves time, and makes the lumber-buying experience smoother and more efficient.