The New Miller® Copilot™ Builder™ With Blue iQ™ Brings Adaptive Automation to Real-World Fabrication Environments

Adaptive-intelligence automation that adapts to changing fabrication conditions

APPLETON, Wis.--(BUSINESS WIRE)--Miller Electric Mfg. LLC, a leading manufacturer of arc welding equipment, today announced the launch of the Copilot Builder with Blue iQ, powered by NovAI™. Developed in collaboration with Novarc Technologies, the welding system is designed to help fabricators bring robotic welding to applications that have traditionally been difficult to automate due to part variation, fit-up inconsistencies, tack welds and the challenges associated with large, complex fabrications.

Many fabrication jobs remain beyond the reach of conventional automation because weld conditions are not always predictable. Copilot Builder with Blue iQ uses adaptive intelligence to continuously respond to weld variation in real time, helping fabricators take on more applications without extensive reprogramming or expensive fixtures.

“The value of automation is well established, but many fabrication applications have remained difficult to address with conventional systems where conditions aren’t always predictable,” said Sam Harvey, business unit director, Miller Electric. “Fabricators need solutions that fit the realities of their operations, where part fit-up, joint conditions and production demands can change from one job to the next. With Copilot Builder with Blue iQ, the system can adapt to variation as it occurs, helping manufacturers automate a broader range of welding applications, improve productivity and make better use of their skilled workforce while maintaining the flexibility their operations demand.”

“Fabricators supplying data centers, shipbuilding, energy infrastructure and heavy equipment are facing a growing shortage of skilled welders, programmers and challenges related to part variability in their robotic welding operations. Harnessing our vast amount of welding data, we are excited to bring our Physical AI platform to the Copilot Builder to solve these robotic welding challenges. NovAI™, our AI-powered computer vision solution, performs real-time adaptive welding with no prior joint scanning. Through our partnership, welding automation can now be achieved across a broader range of welding applications," said Soroush Karimzadeh, CEO and co-founder of Novarc Technologies.

The Copilot Builder with Blue iQ, powered by NovAI™, will be integrated with NovHub™, Novarc’s centralized Enterprise Welding Intelligence platform that brings visibility to robotic and mechanized welding operations by connecting weld data, video, process parameters, and production records. This extends the system's capabilities by converting production data into actionable insights.

Key technologies within Copilot Builder with Blue iQ, powered by NovAI™, include:

• NovAI™ Autonomy: Uses machine vision, real-time adaptation and adaptive control to help compensate for gaps, misalignments and part variation during welding.
• Adaptability to Variation: Designed to address fit-up variability, tack consumption and changing weld conditions without constant reprogramming.
• Flexible Deployment: Portable system design helps bring robotic welding into existing workspaces rather than requiring parts to fit traditional weld cells.
• Traceability with NovHub™: Captures and analyzes weld data through a centralized platform that provides insight, traceability and optimization opportunities.

The system can be mounted on horizontal, vertical and inverted surfaces to accommodate different workspaces and part geometries and to better integrate into existing workflows. Remote operation helps improve safety by allowing operators to work farther from heat and fumes, while integrated data supports continuous process improvement over time.

To learn more about how Copilot Builder with Blue iQ helps fabricators address weld variation and expand the range of applications suitable for robotic welding, visit www.millerwelds.com/en-us/automation/welding-automation-systems/copilot.

About Miller

Miller Electric Mfg. LLC, headquartered in Appleton, Wisconsin, is a leading worldwide manufacturer of Miller^® brand arc welding products and is a wholly owned subsidiary of Illinois Tool Works Inc. (NYSE: ITW). For more information, visit MillerWelds.com, call 1-800-4-A-Miller (800-426-4553), email [e-mail], fax [phone], or write to Miller Electric Mfg. LLC, P.O. Box 100, Lithonia, GA 30058.

About Novarc Technologies Inc.

Novarc Technologies is the industrial Physical AI company reinventing welding automation for the global fabrication industry by pioneering enterprise welding intelligence. Novarc activates arc welding robots with perception and cognition. With no visual intelligence these industrial robots currently make costly errors that lead to rework, scrap, rebuilds and downtime. Novarc’s Physical AI platform combines real-time computer vision, adaptive control and welding intelligence, with over-the-air software updates to transform robotic welding systems into continuously improving Physical AI endpoints. For more information, visit www.novarc.ai.

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