The usage of collaborative robots has significantly increased over the years, revolutionizing the way industrial units function. For these and many other driving factors, there is a huge market for cobots. With the right protective covers or suits and advanced robots, humans and machines can work efficiently in the same space. As per a research report, the cobot market in the USA is expected to reach USD 1,401.5 million by 2030, reflecting a compound annual growth rate (CAGR) of 29.5% from 2025 to 2030. This surge is driven by their ability to enhance productivity and affordability across sectors, such as manufacturing, logistics, and healthcare, and co-work alongside humans. However, their exposure to harsh industrial environments necessitates robust protection to ensure longevity and optimal performance. Robot suits, popularly called robot protective covers, are designed to protect cobots from environmental and operational stressors. This post discusses why protective covers matter, and how do they protect cobots across industries.
Why Cobot Protection Matters?
Cobots are designed to work alongside humans in industrial settings, performing various tasks such as welding and material handling without safety cages. This close interaction exposes them to hazards, including dust, moisture, chemicals, and physical impacts. Without protection, the critical components of cobots, such as sensors and motors, are vulnerable to damage. This vulnerability can lead to increased downtime, costly repairs, and compromised performance. It can also pose a risk to humans working alongside. Industrial robot covers, or cobot protective suits, serve as a barrier against these threats, helping to maintain operational continuity and extend equipment lifespan. They support compliance with workplace safety regulations and protect significant capital investments by reducing maintenance needs and maximizing the return on investment in automated systems. The following section outlines the challenges in the use of cobots and how robot suits address them.
Real-World Challenges for Cobots and How Protective Suits Solve Them
Being integrated into demanding industrial environments, they encounter several operational hazards, compromising their performance and longevity. Here are some pointers that describe how well-designed robot protective suits, like the Robot-Flex series, provide practical solutions to these everyday challenges.
- Physical Damage: Cobots can handle various tasks, such as lifting heavy materials, grinding, welding, and so on. During these tasks, they often face flying sparks, debris, and occasional bumps from nearby equipment. These repeated impacts can wear down or even damage the cobot’s arms and outer casing over time. Protective suits made from impact-resistant and heat-resistant materials act like armor for the cobot. They absorb shocks and deflect abrasive particles, shielding the machine from physical damage.
- Environmental Exposure: Cobots operating in food processing, machining, or automotive manufacturing are exposed to contaminants such as dust, water, coolants, oil, and chemicals. These elements can seep into joints and sensors, leading to corrosion or mechanical failure. Robot protective suits form a durable shield around vulnerable components, repelling liquids, and airborne particles. With materials engineered to resist industrial chemicals and moisture, these covers keep cobots operational even in the most challenging environments.
- Sensor and Gripper Interference: Sensors located in grippers and end-effectors are vital for precision tasks, but exposure to dirt, fluids, or airborne particles can disrupt their accuracy and responsiveness. Precision-designed suits feature targeted coverage that protects these sensitive components without restricting their movement or range of motion, ensuring continued functionality and safety.
- Condensation and Humidity: In facilities with high humidity or fluctuating temperatures, condensation can build up inside cobot housings, posing a serious threat to sensitive electronics and leading to rust or short circuits. Advanced protective covers are designed to manage moisture and prevent condensation. These breathable yet sealed barriers help regulate temperature and humidity around the cobot, protecting internal systems from long-term damage.
- Machine Downtime: Time-consuming installation or removal of protection can lead to unnecessary downtime during routine inspections or repairs, affecting productivity. Robot-Flex suits are engineered for quick and easy installation, allowing maintenance teams to access the cobot quickly without compromising protection. This ensures minimal disruption to production schedules.
Top Industries That Use Robot Protective Suits for Safety and Efficiency
Here is a list of industries that benefit from using robot protective suits.
- Food & Beverage: Cobots in food processing and packaging are exposed to moisture, steam, and cleaning agents. Food-safe, washable robot suits prevent contamination, resist corrosion, and ensure compliance with hygiene standards, supporting reliable automation in high-volume tasks.
- Manufacturing: Cobots in automotive, electronics, and metal fabrication face exposure to abrasive dust, metal shavings, oils, and chemicals. Protective suits shield sensitive components, preserving precision and ensuring consistency in high-speed production environments.
- Pharmaceuticals: In cleanroom settings, cobots must avoid contaminants that can affect delicate processes. Cleanroom-compatible suits minimize particle generation, ensuring safety and compliance in pharmaceutical manufacturing.
- Logistics & Warehousing: In dynamic supply chain environments, cobots deal with constant movement, impacts, and temperature changes. Protective covers absorb shocks, prevent wear, and shield electronics, enhancing durability and reducing downtime.
Factors to Consider When Selecting a Protective Suit for Your Cobot
Selecting protective cobot suits seems like an easy and straightforward process. However, here are some important factors that you should consider.
- Select a suit that can withstand specific environmental conditions, such as moisture, dust, or chemicals.
- Ensure a protective suit is made from durable materials such as polyurethane or aramid fibers, which are resistant to wear and tear.
- The suit should allow the robot to move freely and perform tasks without hindrance or restricted motion.
- Select a protective suit that is easy to clean, especially if the robot operates in hygiene-sensitive environments.
- Ensure the suit offers impact protection, temperature resistance, and sensor protection.
- Verify that the protective suit meets the necessary safety and regulatory standards for your specific industry.
- Consider both the quality of the material and the long-term cost savings in terms of reduced maintenance and downtime.
- Depending on the robot’s tasks and environmental conditions, customized protective suits should be considered to meet unique needs.
Looking for the best protection for your cobots? Nabell USA Corporation is a one-stop solution. With the NRF Series of Robot-Flex protective suits, designed specifically for top brands like FANUC, Yaskawa, Techman and Universal Robots, you’ll get the highest level of protection and durability. These covers are a blend of traditional manufacturing techniques and advanced 3D printing to protect against harsh environmental factors. Whether you need a Fanuc robot cover or a Yaskawa robot cover, Nabell has you covered. Contact our experts today to customize your robot arm covers and enhance your cobot’s performance and longevity.