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Assembly Systems

FLEXBASE Modular Assembly & Automation Systems

Automated Assembly and Test
Life Sciences

Tooling Tech Group’s FLEXBASE modular automation cell is a perfect manufacturing solution for meeting the demands of the medical device industry. FLEXBASE systems are designed to quickly automate processes and build accuracy, reliability, repeatability and consistency into manufacturing processes as well as being Clean Room ISO 8 compliant. Plus, these standard, modular work cells get manufacturers up and running with production of medical equipment in no time. These work cells can easily be programmed to automate processes such as dispensing, sorting, welding, fastening or testing of medical supplies and biomedical devices.

Check out our 3-minute introduction to Flexbase

Plus, we offer Mold & Die Tooling:  FLEXBASE systems, combined with Tooling Tech Group’s mold, die and tooling capability, enable medical companies to turn to one source for many of their manufacturing needs. For example, we’ve made thermoform tools for MRI machine and dental chair covers and blow molds for plastic bottles and reservoirs.

Reduce Cost and Time to Launch
While Continually Maintaining Product Quality

All manufacturers are challenged with reducing cost and time to launch while continually maintaining product quality. These issues can be addressed by replacing repetitive manual operations with the FLEXBASE modular automated work cell. These flexible and scalable systems are designed to easily integrate robotics, vision, lasers or other technologies to drive reliability, repeatability and affordability into your operations. Available in a 4-ft or 6-ft base size, the FLEXBASE can be configured as a standalone, automated workstation or linked together via conveyors to quickly create a complete robotic assembly line.

single machine
  • Clean Room ISO 8 compliant; clean and easy to wipe down
  • Can be FDA validated with documentation package
  • Easy to modify from manual to semi-automated to fully-automated
  • Ergonomically designed to accommodate a standing or sitting operator
  • Faster deployment than custom automation and is highly scalable
  • Easy to modify an existing cell into a different application
  • Maximum height with guarding is 7’6” to allow for passage through a standard 8′ doorway
  • Bases have rollers for easy transport with built-in levelers
  • Low risk plug-and-play approach

Things that can be done using


  • Robotic / Servo Control Integration
  • Robotic Integration
  • Conveyance
  • Rotary Dial Indexers


  • Press with Preload and Rotary Compensation
  • Press to Force and/or Distance
  • Nutrunners
  • Orbital Forming
  • Heat Staking
  • Adhesive


  • Machine Vision Inspection
  • Pressure Decay Leak Test
  • Flow Test
  • Electrical Properties
  • Dimensional Gauging (Vision/Laser/Physical)
  • High Pressure Proof Testing


  • Laser, Inkjet, Impact Marking
  • Barcode
  • 2D Matrix
  • RFID Systems
  • Barcode Labeling
  • Traceability


  • Incoming Material Lot Control
  • Assembly Birth Certificates
  • SPC Data Collection / Monitoring
  • Traceability


  • Synchronous/Asynchronous Processes
  • High-speed Assembly
  • Small Parts Assembly
  • Multiple Product Capability

Dispensing and Sorting

  • Volumetric
  • Weight
  • Coordinated Motion Bead Path
  • Large Bulk Container Management
  • Vibratory


  • Ultrasonic
  • Resistance
  • Friction
  • Wave soldering
  • Plasma
  • MIG
What Comes with the
Standard Flexbase

Each FLEXBASE comes with fully integrated vision and controls that adapt to a variety of robot and tooling options, which are easily retooled for product changes. And, FLEXBASE is a clean room ISO 8 compliant solution.

Machine Base

  • Fully welded steel frame
  • Powder coated to customer’s specifications
  • Leveling feet
  • Powder coated skins on right hand and left hand sides
double machine


  • Extruded guarding frame
  • Removable Lexan panels on top and sides
  • Lexan doors in front and rear with hinges and handles
  • Interlocked door safety switches on doors
  • Mounting bracket with stack light
  • Banner LED lighting for work area


  • Allen Bradley Compact GuardLogix® 5380 Safety Controller
  • Allen Bradley 1734 Point IO Adapter
  • Allen Bradley includes Safety and Non-Safety IO modules
  • Control Panel with 30-Amp Disconnect Switch
  • Circuit Protection
  • 24 VDC Power Supply
  • Safety Circuit
  • 8 Port Managed Ethernet Switch
  • 24 Port POE+ enabled Ethernet Switch
  • Programming Port
  • 8 Port Managed Ethernet Switch
  • 24 Port POE+ enabled Ethernet Switch
  • (3) Station Pushbutton Box
  • (1) PB Station with E-stop (x2)
  • (2) POE Web Cameras (for remote/external monitoring only)
  • (3) Segment LED Light Stack with Horn (IO-Link Enabled)
  • UPS for 208/240VAC Input to 120-208/240 VAC Output
  • Industrial Computer with Touchscreen
  • IFM IO-Link Master
  • SMC Ethernet/IP 8 Station Valve Bank

Standard Options

  • (1) Cognex DMR-262S-0542-P Barcode Reader at Pre-stop
  • Mounting for webcams
  • Upper and lower Quickdraw conveyor
  • (1) Pre-stop, (1) stop and (1) downstream blocked sensor on the upper conveyor
  • (1) Stop and (1) downstream blocked sensor on the lower conveyor
  • Light curtains in lieu of guard doors
  • No guarding (manual workstation)
  • Web cameras
  • Belt conveyors
  • Lift and locates for precise part location


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Sheet Insertion

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Precision Assembly

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Plastics Assembly

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Piloted Insertion

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Magnetic Turnover

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Laser Welding

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Faucet Assembly

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Automated Sanding

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Automatic Fuse Insertion