Introducing Miller’s Copilot Builder with Blue iQ™, powered by NovAI. Blue iQ is Miller’s true adaptive intelligence technology developed in partnership with Novarc Technologies, bringing advanced responsiveness to challenging welds traditional automation can’t handle. The system automatically adapts to part-to-part variation, fit-up challenges and tack weld consumption making automation possible in environments where consistency is tough to achieve.
Paired with NovHub’s real-time data insight, this solution helps fabricators improve weld quality and stay competitive as demands for productivity and flexibility continue to rise.
This launch reflects a major step forward in making advanced automation more accessible, flexible, and practical for the work that happens every day on the shop floor.
Business challenge |
Capability |
Benefit |
|---|---|---|
| High rework rates |
Blue iQ |
Adapts to real-world conditions in real time to identify gaps and variations, automatically adjusting the weld path to the joint. |
| Variations in parts make implementing automation challenging | Blue iQ | Lower requirements for fixturing and fit up. Real-time control of welding condition to account for variances. |
| Skilled labor is difficult to find | Easy-to-operate user interface and teach tools | Advanced welding automation is easier to learn and operate on the Copilot Builder system without needing hard-to-find expert programmers and highly specialized welders. |
| Traditional welding automation is difficult to program and operate | Intuitive user interface and teach controls | Intuitive tools like IntelliSet™, AccuGuide™, touch sensing, and a simple programming puck to eliminate the complex programming and setup traditional welding robots require. |
| Parts are large and don't fit inside a traditional welding automation cell | System flexibility | Copilot Builder is modular and allows the user to arrange the arm and components in a way that suit their environment instead of making the environment suit the equipment. |
| Part tracking requirements for quality purposes | NovHub | Cloud based data storage ensures everything you need to know about each weld is captured and stored. |
| Welding is difficult work and not always ergonomical |
Monitor and teach pendent | Copilot Builder and Blue iQ allows the welder to stay away from the weld plume and heat while still monitoring the weld through the monitor and controlling with the teach pendent if necessary. |
The Copilot Builder with BlueIQ™ is an adaptive welding automation system designed to handle the real-world joints, variation, fit-up conditions and tack consumption that traditional automation struggles with. It adjusts to the work rather than forcing fabricators to adapt their parts or processes.
The Blue iQ technology allows the Copilot Builder to make these real-time adjustments:
- Travel speed
- Wire feed speed
- Arc length
- Targeting position
- Weave width
- Weave frequency
- Weave dwell
Blue iQ uses optical vision, 2D laser vision, path generation, pre-configured weld settings and through arc tracking to make it all happen.
Fabricators who need automation but can’t fully automate today because their parts don’t fit in a traditional welding cell, are inconsistent, or require too much variation handling. It’s built for structural, heavy fabrication, and mixed production environments.
It reduces rework caused by fit-up variation, improves welder ergonomics by enabling remote operation and monitoring, and provides real-time data visibility that many shops currently lack.
For those who are already familiar with automation, it saves touch up time for part variations, overwelding to accommodate fit up and tacks, and extensive touch sensing.
The system is being unveiled at NASCC, with expected launch in Q3 2026.
Yes, our welding procedures can be qualified to the applicable AWS codes (e.g., D1.1, D1.5, D15.1, D14.3).
At launch, Miller’s Copilot Builder with Blue iQ will have several joint types and positions available.
Carbon Steel:
• T-Joint – 1F, 2F, 3F
• Lap Joint – 1F, 2F
• V-Groove – 1G, 2G
• Single-Bevel Groove – 1G, 2G (Available late 2026)
“For decades, a huge portion of fabrication work has been considered ‘unautomatable’ because parts varied too much or conditions were too inconsistent. With the Copilot Builder and Blue iQ, we’re breaking that barrier wide open. This launch finally brings automation to the real world jobs that were always out of reach and that’s going to change what fabricators can take on, how they work, and how competitive they can be.”
- Jake Zwayer, Vice President & General Manager, Industrial Equipment & Automation, Miller Electric Mfg. LLC
“Fabricators, especially in the structural steel industry, have told us for years that their parts vary too much, skilled labor is hard to find, and traditional automation just isn’t built for the kind of work they do. With the Copilot Builder and Blue iQ, we’re solving those pain points head-on. This system adapts to their real world challenges, simplifies programming, and gives them the confidence that automation will finally work in their environment, not just in ideal conditions.”
- Sam Harvey, Business Unit Director, Industrial Equipment & Automation, Miller Electric Mfg. LLC
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