PushCorp
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PushCorp is the leading manufacturer of robotic material removal end-of-arm tooling.
09/30/2026
Fatigue shouldn’t be a process variable.
Yet in manual grinding, sanding, and deburring, quality often depends on an operator maintaining the same force, angle, and dwell time for hours.
As fatigue builds, the process can drift.
A little more pressure here.
A slightly longer pass there.
A missed burr on the next part.
Those small differences can turn into rework, scrap, premature abrasive changes, and delays that travel into welding, coating, and assembly.
Using cobots for material removal offers another approach. 🦾
Paired with the right tooling and force compliance, they can repeat the same motion and maintain controlled pressure from the first part of the shift to the last. They are particularly useful where flexibility, quick changeovers, and a smaller automation footprint matter.
PushCorp breaks down where cobots fit, the processes they can automate, and the six building blocks of a repeatable material removal cell in this article:
https://pushcorp.com/blog/material-removal-cobots/
For visible metal parts, the grain pattern is part of the final product.
On stainless steel surfaces, inconsistent grain direction, scratches, mill scale, or uneven blending can quickly reduce the perceived quality of the finished part.
Robotic graining helps make that finish repeatable. 🦾
By controlling abrasive pressure, direction, and tool motion, the robot can establish a uniform grain pattern across every part.
In this PushCorp demo, tool selection made an important difference.
A pneumatic contact wheel performed better than an expander-style wheel because its inflation level can be adjusted to change how much the wheel conforms to the surface.
That allows it to:
✅ Reach into low spots and shallow valleys
✅ Follow surface variation without excessive stock removal
✅ Run at lower speeds while keeping the abrasive belt securely in place
Combined with controlled robotic motion and force, that conformability helps create a more uniform grain without unnecessarily altering the part geometry.
For cosmetic metal finishing, the goal is controlled and consistent surface refinement.
See it in action:
09/24/2026
Grinding welds for nearly an entire shift is not a great use of skilled welding labor.
That was the challenge at Expedition One.
Before automation, welders were spending 60–90 minutes grinding each bumper. For a process repeated throughout the day, grinding quickly became a major drain on skilled labor and production capacity.
After implementing a PushCorp robotic grinding solution, that same grinding process dropped to 8–10 minutes per bumper. 🦾
That is up to 9× faster grinding.
But the bigger win was what happened to the welders.
Instead of spending most of the day grinding completed welds, they could get back to welding and other productive work where their skill creates more value.
✅ Less time spent on manual grinding
✅ More welding capacity
✅ Faster finishing cycles
✅ Skilled labor focused on skilled work
Expedition One’s results show why robotic grinding ROI is not only about cycle time. Sometimes the biggest gain is simply giving valuable labor back to production.
👉 See the full Expedition One success story: https://www.youtube.com/watch?v=61SbdHcRuG0
The edge profile you need should determine how you remove the material.
For a defined bevel, a bevel head cutter can machine the edge at a controlled angle, such as the 45° bevel shown in this demo. Instead of grinding the edge down with an abrasive, the cutter removes material as metal chips.
That also brings an important process advantage:
✅ Less airborne grinding dust
✅ Defined bevel geometry
✅ Cleaner material removal
✅ Easier collection of chips compared with fine abrasive debris
For smooth radiused edges, force control becomes especially important. As the abrasive moves around the edge, the contact conditions change continuously.
A robotic spindle paired with active compliance can maintain controlled pressure through that transition, helping produce a smoother and more repeatable radius. 🦾
See the PushCorp demo in action:
09/22/2026
A grinding injury does not end with the medical bill. ⚠️
In this example, a single workers’ comp claim can reach $140,000+.
That number alone gets attention. But the bigger cost is everything that happens around the claim.
💵 The direct cost:
Treatment, compensation, and time away from work.
🏭 The production cost:
Someone has to cover the missing worker. Output may slow. Overtime can rise. Supervisors lose time dealing with the incident instead of production.
📈 The long-term cost:
Even after the claim is closed, higher insurance premiums can continue for years.
And grinding carries several sources of exposure at once:
⚠️ Rotating abrasives and sparks
⚠️ Dust and debris
⚠️ Vibration and repetitive physical effort
⚠️ Awkward working positions
Even if serious incidents are infrequent, the financial impact of a single injury can be substantial.
Robotic grinding changes that equation by moving the operator away from the tool and reducing direct exposure to the process. 🦾
But safety is only one hidden cost of manual grinding. Most manufacturers never analyze the indirect costs of grinding and finishing their parts manually.
That’s why we created a free guide that breaks down 20 hidden costs of manual grinding, including injuries, labor shortages, turnover, overtime, lost throughput, rework, and missed business.
👉 Download the free guide here: https://pushcorp.com/guide-manual-grinding-20-hidden-costs/
Curved surfaces make consistent robotic finishing difficult.
As a grinding or sanding tool follows changing geometry, the contact angle alters continuously. So, maintaining the right pressure across the entire surface becomes critical.
Active compliance adjusts the applied force in real time as the robot moves across the part.
That helps maintain:
✅ Consistent abrasive contact
✅ Uniform material removal
✅ Smooth transitions across changing geometry
✅ Repeatable finish quality
For robotic grinding, sanding, and finishing on curved parts, that ability to maintain controlled force is what helps keep the process consistent.
Using the right compliance type and device can make or break the automation effort.
See PushCorp in action on curved surfaces:
What makes an electric spindle useful for robotic material removal? 🤔
For many grinding, deburring, and finishing applications, it comes down to consistent speed and a compact design.
Electric spindles can maintain steady abrasive speed during material removal while keeping the tooling lightweight enough for the robot to move easily around edges, corners, and complex parts.
That makes them a good fit for applications such as:
✅ Weld grinding
✅ Edge blending
✅ Deburring
✅ Surface finishing
The result is controlled material removal with more consistent finishes from part to part. 🦾
This video shows PushCorp’s 2.0 hp electric spindle across several robotic material removal applications.
09/15/2026
IMTS 2026 is underway. 🦾
PushCorp is live in Chicago with KUKA and SCHUNK, demonstrating new robotic foundry and material removal solutions on the show floor.
If you’re attending IMTS this week, stop by to see:
✅ Live robotic application demonstrations
✅ New foundry automation approaches
✅ Heavy-duty material removal technology
✅ PushCorp’s largest-format servo motor spindle yet
It is also a chance to bring your own grinding, cutoff, finishing, or foundry application questions and talk directly with the teams behind the technology.
PUSHCORP × KUKA × SCHUNK
📍 KUKA Booth #236807, North Building
📅 September 14–19
Come see the applications running live at IMTS.
09/10/2026
4 days until IMTS 2026 and PushCorp’s unveiling of its largest-format servo motor spindle yet, developed for heavy-duty applications.⚙️🦾
PushCorp is heading to Chicago with KUKA and SCHUNK for live demonstrations built around demanding robotic foundry and material removal applications.
At the show, visitors will be able to see new automation approaches for processes where power, rigidity, tooling, and process control all have to work together.
If grinding, cutoff, finishing, or foundry automation is on your roadmap, bring your application questions and talk directly with the teams behind the technology.
PUSHCORP × KUKA × SCHUNK
📍 KUKA Booth #236807, North Building
📅 September 14–19, 2026
See you at IMTS.
A robotic saw can do more than just separate aluminum castings from the tree.
Done correctly, it can also reduce the amount of cleanup needed afterward. 🦾
In one of our recent demos, we used a high-power spindle with a 10-inch carbide blade to cut lost foam aluminum castings directly from the risers.
The testing focused on what it takes to make robotic cutoff useful beyond basic part separation:
✅ Cut closer to the finished surface
✅ Maintain repeatability across multiple risers
✅ Reduce hands-on work around the saw
✅ Minimize material left for secondary sanding
Getting there depends on the entire cutting strategy. Blade position, cut angle, sequence, and part support all influence how cleanly each component separates.
Every bit of riser material left behind can mean more finishing work downstream.
And if robotic foundry automation is on your radar, see what PushCorp is bringing to IMTS 2026. 🦾
PushCorp will join KUKA and SCHUNK for live demonstrations of new robotic foundry solutions and unveil its largest-format servo motor spindle yet, developed for heavy-duty applications.
📍 KUKA Booth, North Building #236807
📅 September 14–19
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3001 W Kingsley Road
Garland, TX
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