Copilot Builder enables welding with AI

Enter the new era of welding automation; built for real world fabrication, not perfect world scenarios. 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. | 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. | What is the Copilot Builder with Blue iQ? 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. What makes the Blue iQ technology truly adaptive? 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. Who is this system designed for? 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. What problems does it solve for fabricators? 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. When will the Copilot Builder with Blue iQ be available? The system is being unveiled at NASCC, with expected launch in Q3 2026. Do welds produced with Copilot Builder with Blue iQ meet industry codes? Yes, our welding procedures can be qualified to the applicable AWS codes (e.g., D1.1, D1.5, D15.1, D14.3). What types of joints or applications can it handle? 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)