The HGG RoboRail is a compact, all-in-one robotic plasma cutting machine designed to automate the cutting and profiling of miscellaneous steel components. Engineered for fabrication shops producing stairs, handrails, railings, structural supports, and custom steel assemblies, the RoboRail combines multiple cutting and layout operations into one efficient production system.
Using a high-precision Stäubli industrial robot and Hypertherm plasma cutting technology, the RoboRail processes a wide variety of materials, including round pipe, square and rectangular tubing, channels, angles, and flat bar. The machine performs cut-to-length operations, copes, notches, holes, and layout marking directly from digital design information, helping reduce manual measuring, cutting, and secondary fabrication work.
The RoboRail features a protected cutting environment, stable heavy-duty machine base, and configurable material handling system. Its compact footprint makes it an excellent choice for shops seeking to introduce robotic automation without dedicating extensive floor space to multiple fabrication machines.
Advanced CAD/CAM integration allows the RoboRail to process DSTV and STEP files from compatible detailing software, including SDS2, Tekla Structures, SolidWorks, and Autodesk Inventor. This direct connection between engineering and production helps minimize programming time, reduce human error, and simplify the processing of unique components.
With intuitive machine controls and streamlined production workflows, the RoboRail makes robotic cutting technology accessible to fabricators looking to increase productivity, improve cutting accuracy, and reduce their dependence on time-consuming manual operations.
All-in-One Robotic Plasma Cutting
Combines cutting, coping, notching, hole cutting, and layout marking in one machine
Processes a wide variety of miscellaneous steel profiles
Reduces the need for multiple cutting and fabrication workstations
High-Precision Stäubli Robotic Arm
Industrial robotic cutting technology delivers consistent, repeatable positioning
Performs complex cutting geometries on different material profiles
Supports accurate automated processing of unique and repeated components
Versatile Multi-Profile Processing
Processes round pipe, square and rectangular tubing, channels, angles, and flat bar
Accommodates round pipe diameters from 1″ to 10″
Handles square tubing up to 8″ x 8″ and other supported structural profiles
Reliable Hypertherm Plasma Technology
Integrated plasma cutting system delivers efficient processing of steel components
Supports material thicknesses from 1/8″ to 3/4″
Produces accurate cuts, holes, and notches for fabrication and assembly
Compact, Protected Cutting Environment
Enclosed robotic cutting cell helps contain the cutting process
Heavy-duty machine base provides stability during operation
Optional safety fencing supports a controlled production environment
Intelligent CAD/CAM Integration
Supports direct processing of compatible DSTV and STEP files
Integrates with SDS2, Tekla Structures, SolidWorks, and Autodesk Inventor
Reduces manual programming and simplifies complex part preparation
Automated Material Feeding & Positioning
Accommodates infeed material lengths up to 24 feet
Supports finished-part outfeed lengths up to 8 feet
Integrated material positioning enables efficient cutting of varied profiles
Intuitive Operator Interface & Fast Setup
User-friendly controls guide operators through machine operation
Simplified programming reduces dependence on extensive manual layout skills
Compact modular design supports efficient installation and commissioning
Increase Fabrication Productivity
Automate repetitive cutting, coping, notching, and layout operations
Reduce processing time compared to traditional manual fabrication methods
Increase throughput without relying on additional manual cutting stations
Reduce Manual Labor & Production Costs
Eliminate time-consuming manual measuring and layout for programmed parts
Reduce dependence on skilled labor for repetitive cutting operations
Allow fabricators to focus on assembly, welding, and higher-value tasks
Improve Cutting Accuracy & Consistency
Produce repeatable cutting geometries using industrial robotic technology
Reduce human error associated with manual layout and cutting
Improve part fit-up and consistency across different production runs
Process Multiple Steel Profiles on One Machine
Cut pipe, tubing, channels, angles, and flat bar using one integrated system
Eliminate unnecessary movement between separate fabrication workstations
Support diverse miscellaneous steel fabrication requirements
Optimize Workshop Space & Material Flow
Compact machine footprint reduces floor space requirements
Consolidate multiple cutting operations into a single production area
Improve material handling and shop organization
Streamline CAD-to-Cutting Workflows
Import compatible DSTV and STEP files directly from detailing software
Reduce manual programming and production preparation time
Improve consistency between digital designs and finished components
Improve Workplace Safety & Operator Efficiency
Protected cutting environment helps isolate the plasma cutting process
Optional safety fencing supports safer material processing
Guided machine controls simplify operation and reduce training requirements
Support Faster Project Turnaround
Reduce cutting and preparation time for stairs, handrails, railings, and structural components
Process unique and repeated parts efficiently without extensive manual setup
Improve scheduling flexibility and respond more effectively to changing production demands
| RoboRail Specifications | ||
|---|---|---|
| Profile Type | Minimum Size | Maximum Size |
| Pipe Diameter | 1 inch (25 mm) | 10 inches (250 mm) |
| Box Section | 1 x 1 inch (25 x 25 mm) | 8 x 8 inches (200 x 200 mm) |
| Channel Width | 3 inches (75 mm) | 12 inches (300 mm) |
| Angle Size | 1 x 1 inch (25 x 25 mm) | 8 x 8 inches (200 x 200 mm) |
| Material Thickness | 1/8 inch (3 mm) to 3/4 inch (20 mm) | |
| Infeed Length | Up to 24 feet (7,315 mm) | |
| Outfeed Length | Up to 8 feet (2,500 mm) | |
| Maximum Infeed Weight | 882 lbs (400 kg) | |
| Cutting Process | Plasma Cutting | |
| Marking Options | Layout Marking Available | |
| CAD Integration | Compatible with SDS2, Tekla, SolidWorks, Inventor, and more | |
A: The HGG RoboRail is an all-in-one robotic plasma cutting machine designed for miscellaneous steel fabrication.
It automates cut-to-length operations, coping, notching, hole cutting, and layout marking on a variety of structural steel profiles.
The RoboRail is particularly well suited for fabricators producing:
Stair stringers and stair components
Handrails and guardrails
Structural tubing assemblies
Miscellaneous steel supports
Channels and angle components
Round pipe connections
Custom steel fabrication projects
By combining multiple cutting operations into one automated system, the RoboRail helps reduce manual layout, cutting, and material handling while improving production consistency.
A: The RoboRail is designed to process a variety of common miscellaneous steel profiles, including round pipe, square and rectangular tubing, channels, angles, and flat bar.
Supported material capacities include:
Round pipe: 1″ to 10″ outside diameter
Square tubing: 1″ × 1″ up to 8″ × 8″
Channels: from approximately 2″ × 1½” to 11″ × 3¾”
Angles: 1″ × 1″ up to 8″ × 8″
Flat bar: approximately ⅜” × 2″ up to ¾” × 11″
Material thickness: ⅛” to ¾”
The RoboRail accommodates material infeed lengths up to 24 feet, with finished-part outfeed lengths up to approximately 8 feet.
Actual cutting capacity depends on material geometry, thickness, and machine configuration.
A: The RoboRail performs a wide range of robotic plasma cutting and profiling operations used in miscellaneous steel fabrication.
These include:
Cut-to-length operations
Straight and angled cuts
Pipe and tube coping
Notches and relief cuts
Bolt holes and connection holes
Complex profile intersections
Stair stringer and handrail cutting geometries
Layout and reference marking
Using digital cutting information, the RoboRail produces repeatable part geometries without requiring extensive manual measuring or layout.
This helps simplify downstream fitting, welding, and assembly.
A: The RoboRail can significantly reduce processing time by automating manual layout, cutting, notching, and hole preparation.
In one documented application, a pipe cutting operation that required approximately five minutes manually was completed by the RoboRail in approximately 30 seconds.
Another customer application demonstrated that a complex cut-to-length and notching operation, which traditionally required around 80 minutes of manual preparation and processing, could be completed in approximately five minutes using the RoboRail.
Actual productivity improvements depend on part geometry, material type, operator workflow, and existing fabrication methods.
By reducing manual processing time, the RoboRail allows fabrication teams to increase throughput and dedicate more labor to fitting, welding, and assembly.
A: Yes. The RoboRail supports direct processing of compatible DSTV and STEP files, allowing cutting information to be transferred from digital models into production.
Compatible detailing and CAD systems include:
SDS2
Tekla Structures
SolidWorks
Autodesk Inventor
Additional systems capable of producing supported file formats
This integration reduces the need for manual programming and helps maintain consistency between engineering designs and finished components.
The RoboRail is especially useful for miscellaneous steel fabricators processing unique parts, where every component may require a different cutting geometry.
A: Yes. The RoboRail is designed to make robotic plasma cutting accessible to fabrication shops that want to increase automation without installing several separate cutting machines.
Its compact, integrated design combines robotic cutting, material positioning, and a protected cutting environment into one production system.
The machine is particularly valuable for shops that regularly produce stairs, railings, structural supports, and miscellaneous steel components.
By reducing manual layout and cutting requirements, the RoboRail can help smaller teams handle more work while maintaining consistent part quality.
The best fit depends on your material sizes, production volume, available floor space, and current fabrication processes.
A: The RoboRail features a protected cutting cell designed to help isolate the robotic plasma cutting process from the surrounding fabrication area.
Available safety features and equipment include:
Enclosed robotic cutting environment
Optional perimeter safety fencing
Controlled material feeding and positioning
Operator interface positioned outside the cutting area
Integrated machine controls and safety systems
Safety fencing can be supplied as part of the machine installation or incorporated into a facility-specific layout.
Final safety requirements depend on the installed configuration, applicable regulations, and the customer’s operating environment.
A: The RoboRail is an excellent solution for shops that regularly process multiple types of structural steel profiles and want to reduce manual cutting and layout operations.
Important considerations include:
Types of steel profiles being processed
Minimum and maximum material dimensions
Material thickness and weight
Required cutting, coping, and notching operations
Production volume and part complexity
Existing CAD/CAM or detailing software
Available workshop space
Current labor requirements and production bottlenecks
Material loading and unloading workflow
The RoboRail is especially beneficial for stair, railing, handrail, and miscellaneous steel fabricators seeking to consolidate several manual processes into one automated cutting system.
Bramac Machinery can review your materials, production requirements, and facility layout to help determine whether the RoboRail is the right fit for your operation.
