Refurbishing Robotic Waterjet Systems: A Smarter, More Affordable Path to Modern Performance

In the world of automotive manufacturing, precision and uptime drive everything. From cutting carpets and headliners to shaping dashboards, trunk liners, load floors, and insulation parts — every second counts. Yet across North America, countless older robotic waterjet systems built by RPT, KMT, DRS, and Shape Process Automation are reaching the end of their lifecycle. Many of these systems rely on Fanuc robots but are now difficult — and in some cases, impossible — to support.

For Tier-1 suppliers balancing tight budgets and production demands, a full system replacement can be costly and time-consuming. That’s where Alliance Automation, based in Flint, Michigan, offers a smarter alternative: complete refurbishment and modernization of your existing robotic waterjet systems — transforming outdated cells into high-performance, fully supported systems for a fraction of the cost of new equipment.

Why Refurbish Instead of Replace?

The idea is simple — if the core structure of your system is still solid, why start from scratch?

Most legacy robotic waterjet systems from RPT, KMT, DRS, and Shape Process Automation were built with heavy-duty welded frames. What typically fails are the electronics, motion controls, and outdated robots. These components often become unsupported, making replacement parts scarce and repairs difficult.

Alliance Automation’s refurbishment process gives these systems a new life — while saving customers 40–60% compared to building new equipment.

Here’s how we do it.

Our Refurbishment Process: Built on Proven Foundations

Every refurbishment begins with a detailed inspection of your existing system. If the mechanical structure — such as the base, guarding, and cutting enclosure — is still in good shape, we’ll reuse it. These robust frames are sand-blasted, cleaned, and repainted to like-new condition. From there, we rebuild the heart of the system around new technology that meets today’s production and safety standards.

1. New Robots: Faster, Smarter, and Fully Supported

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We replace outdated Fanuc robots with Yaskawa Motoman or ABB models — such as the Motoman GP25 or ABB IRB 2600. These modern 6-axis robots offer:

• Higher accuracy and repeatability
• Faster cycle times
• Speed-independent motion for smoother cutting paths
• Long-term manufacturer support

This translates to higher part quality, greater throughput, and significantly improved uptime.

(Watch this example of Yaskawa’s speed-independent motion in action: YouTube link)

2. New Controls

Each refurbished system is rebuilt with Allen-Bradley PLCs and user-friendly HMI interfaces. Unlike legacy RPT, KMT, DRS, or Shape systems that may be locked down and difficult to modify, our controls are unlocked and customer-accessible.

That means:

• Your engineers can make logic updates or system adjustments as needed.
• You’re not tied to proprietary software.
• Downtime for small program changes is reduced.

It’s your equipment — and we believe you should have full control over it.

3. Updated Safety Systems

We replace outdated safety hardware with Category-4 rated components that comply with current ISO and RIA safety standards. This includes:

• New safety relays
• Light curtains and muting logic
• E-Stops, door interlocks, and robot safety zones

This ensures your refurbished waterjet cell operates not only efficiently, but safely — ready for years of reliable production.

4. Next-Generation Cutting Software

Modern robots deserve modern software. Depending on your preference, Alliance Automation integrates:

• FormCut by Yaskawa Motoman, or
• RobotWare Cutting by ABB

Both provide advanced cutting path control, smooth contour generation, and optimal path management for waterjet applications.

For customers wanting full offline programming capabilities, these refurbished systems can also be paired with RobotMaster CAD-to-Path software or OEM offline packages — something nearly impossible on legacy Fanuc-based systems. Offline programming allows your engineering team to:

• Create and simulate paths directly from CAD models
• Reduce downtime between part changeovers
• Improve process consistency

The result: greater flexibility and shorter launch times for new part programs.

Applications Across the Automotive Industry

Alliance Automation’s refurbished robotic waterjet systems are trusted for a wide range of automotive interior and acoustic trimming applications, including:

• Carpet and load floor cutting
• Roof liners and headliners
• Dashboard insulation and engine covers
• Trunk liners and side trim panels
• Wheel arch liners
• Seatbacks, NVH, and thermal insulation materials

Whether you’re cutting polyurethane foam, fiberglass, PET felt, or laminated composite materials, our rebuilt systems provide precise, repeatable cuts with minimal maintenance requirements.

Performance That Competes with New Systems

A refurbished system from Alliance Automation doesn’t just “work like new” — in many cases, it performs better than the original. The combination of high-speed Yaskawa Motoman GP25 or ABB IRB 2600 robots, advanced controls, and offline programming tools ensures smoother motion, faster cycle times, and improved part consistency.

And because our rebuilds use standard, readily available components, your maintenance team no longer has to struggle sourcing outdated circuit boards or unsupported Fanuc parts. Every component — from the PLC to the HMI — is current, serviceable, and easily replaceable through your local distributors.

The Cost-Effective Advantage

A complete new waterjet system can easily cost hundreds of thousands of dollars. For many Tier-1 suppliers, that level of capital investment isn’t always feasible — especially when existing systems still have a solid mechanical base.

By reusing the main structure and investing in modern controls and robotics, our refurbishment approach provides:

• Major capital savings — often cutting costs by half or more
• Reduced lead times compared to new builds
• Warranty coverage and full service support from Alliance Automation
• Improved energy efficiency and reduced maintenance costs

The result is a system that’s not only affordable but also sustainable, reliable, and future-proof.

A Look Inside the Refurbishment Process

Want to see what a full refurbishment looks like in action?
Watch our recent project here: Full Refurbishment Video

You’ll see how our team:

• Strips down existing waterjet cells to the frame
• Rebuilds them from the ground up with new automation technology
• Delivers like-new performance at a fraction of the cost of new equipment

Each system leaves our Flint, Michigan facility fully tested, programmed, and ready for production.

Alliance Automation: Your Partner for Reliable Waterjet Solutions

Founded and operated in Flint, Michigan, Alliance Automation has earned a reputation as a leader in robotic waterjet cutting systems across the United States. Our experience covers everything from new four-robot gantry systems to complete turnkey refurbishments for Tier-1 automotive suppliers.

Our customers rely on us for:

• American-made engineering and integration
• Expertise in Yaskawa Motoman and ABB robot systems
• Comprehensive service, programming, and support
• Flexible solutions that respect your budget and production goals

We understand the realities of automotive manufacturing — tight timelines, high volumes, and even higher expectations. That’s why our mission is simple: deliver cutting-edge automation solutions that work as hard as you do.

Get More Life — and More Productivity — from Your Existing Equipment

If you’re currently running an older Fanuc-based RPT, KMT, DRS (Dynamic Robotic Solutions), or Shape Process Automation waterjet cell, now is the perfect time to consider an upgrade. Instead of scrapping a structurally sound system, Alliance Automation can transform it into a modern, fully supported robotic waterjet system — equipped with the speed, precision, and reliability your production demands.

Don’t settle for downtime, unsupported components, and outdated performance.
Let Alliance Automation help you modernize for the next decade of manufacturing.