Door Engineering (USA)
About the Company
For more than 60 years, Door Engineering has delivered both custom and pre-engineered industrial, commercial, aviation, and specialty door systems. Their engineering expertise and durable, low-maintenance designs support safe and efficient operation across demanding environments.
The Challenge
Door Engineering manufactures a wide portfolio of custom and pre-engineered door systems — from commercial and industrial four-fold doors to fire-station response doors, hurricane-rated systems, heavy security gates, and large aviation hangar doors. Each product family involves different materials, geometries, and assemblies, and this diversity—combined with a project-driven production model—creates a highly variable welding workload with frequent part changes and the need for fast, precise transitions between jobs. As production volumes grew by nearly 50% and skilled welders became increasingly difficult to hire, the company lacked automation to stabilize throughput and support rising demand.
The Solution
- The project became a multi-stage collaboration as the robotic welding cell evolved alongside changing production needs. The initial setup used touch sensing, but as the company sought faster throughput and smoother adaptation to product variability, the system was upgraded with a laser scanner and redesigned workflows. Over time, the cell went through several iterations as the part portfolio continued to shift—from long, large-format components to shorter and more diverse assemblies—prompting Abagy and the Door Engineering team to continually refine the layout and flow to keep the system efficient across evolving geometries and frequent job changes. Throughout this process, Abagy’s simulation and built-in error-handling tools became increasingly valuable, enabling the team to preview jobs before execution and manage unexpected conditions during production with greater reliability and confidence.
Application/ Implementation
To support consistent quality and efficient delivery, Door Engineering integrated Abagy’s AI- and machine-vision software into a robotic welding system featuring:
Simulation is used to verify setups before production, and accurate part scanning is critical, especially for components with limited surface area on one side. The cell’s robust safety architecture — independent zones and full perimeter guarding — enables safe operation and allows the system to run unattended when required.
- FANUC robot with 3 m reach
- 60-foot track for extended working range
- 4 work zones (2 per side), allowing welding in one zone while loading in another
- Configurable Zone A/B combinations for different part lengths and workflows
- High-performance welding system
- On-site training sessions to help the team optimize operation
Simulation is used to verify setups before production, and accurate part scanning is critical, especially for components with limited surface area on one side. The cell’s robust safety architecture — independent zones and full perimeter guarding — enables safe operation and allows the system to run unattended when required.
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From an engineering standpoint, one of the key outcomes we’ve seen at Door Engineering has been the reduction in rework and the improvement in weld quality and consistency compared to manual welding. The ability to remotely monitor the cell through camera feeds and system diagnostics has also been valuable, allowing the team to respond quickly if any issues arise. Combined with responsive technical support available around the clock, this helped build confidence in integrating the system into day-to-day production.
— Wesley Willenburg,
Engineering Manager, Door Engineering
— Wesley Willenburg,
Engineering Manager, Door Engineering
Outcome
After nearly 2 years with Abagy, Door Engineering strengthened the flexibility and stability of its welding operations, supporting a highly variable, project-driven workflow with autonomous welding and predictable output.
Key Results
- 180+ part models successfully welded with the robotic cell
- Up to four different frame or beam types can be loaded in a single zone
- Simultaneous loading and welding for higher utilization and stable throughput
- 4 Weld zones that can be combined to pre-load multiple parts & produce weldments up to 60 feet in length.
- 2–3 shifts of operation, depending on project load
- Built-in error-handling ensures stable operation, including during unattended shifts
- Reduced rework and improved weld quality and consistency compared to manual welding, especially for critical structural welds
- Automated heat-input control helps prevent distortion on long structural tubes
- Increased output without adding welding labor