Coherix Launches CARES Program to Enhance Adhesive Application Accuracy in Auto Manufacturing

As the automotive industry continues to evolve, manufacturers are shifting from traditional welding methods to high-performance adhesives for assembling key components. This transition, while beneficial for design flexibility and weight reduction, also introduces new risks — particularly when adhesives are improperly applied. In response to these challenges, Coherix, a manufacturing technology company based in Ann Arbor, Michigan, has launched Coherix CARES: a support and maintenance program designed to ensure precision in adhesive dispensing processes.

The Critical Role of Adhesives in Vehicle Safety

Adhesives have become vital in modern vehicles, from securing windshields to sealing electronic systems. “The urethane on glass — that’s all that’s holding that glass in there,” said Dwight Carlson, Coherix’s chairman and CEO. “So that’s a very critical application.” The correct application of adhesives is no longer a mere production detail; it directly impacts passenger safety and vehicle reliability.

Coherix CARES: Closing the Gap Between Robots and Human Precision

Coherix CARES is a subscription-based initiative that supports automotive factories using Coherix’s 3D laser-based inspection systems. These systems evaluate the adhesive path — tracking volume, location, shape, and continuity — to ensure compliance with manufacturer specifications.

According to Jared Rogers, Coherix’s applications engineering manager, the program was created to help customers optimize and sustain their manufacturing processes: “The idea was to create a program to help our customers bring things up to a certain level and help them maintain those using our systems as a tool to provide process feedback.”

Carlson emphasized that while robots play a growing role in adhesive application, human error and a lack of skilled personnel remain significant risks. “The technology going into these plants is increasing all the time, and at the same time, they’re trying to reduce costs anywhere they can. As a result, there’s less skilled people in these plants.”

The Challenges of Robotic Adhesive Application

While robots offer consistency, they lack the intuitive adaptability of humans. Ivy Nguyen, a manufacturing expert and principal at Autotech Ventures, explained that machines require vast training data to perform small adjustments, and even AI-enhanced systems often need reprogramming for larger changes.

“Humans know how to adjust to that on the fly,” said Nguyen. “AI has made it possible to make those micro adjustments on the fly… but at the same time, if you need to make larger changes in how the glue is applied, you probably have to come in and rewrite some of the programs a bit.”

Nguyen also noted that the diversity of equipment from different vendors in modern factories adds another layer of complexity to maintenance and integration — a gap Coherix CARES is designed to help bridge.

Subscription Structure and Early Adoption

The Coherix CARES program is priced on a sliding scale, based on the number of sensors and level of support required. Rogers estimates the cost ranges from $3,000 to $5,000 per system annually.

Since soft-launching the program six months ago, Coherix recently secured its first major subscriber — a well-known Japanese automaker with U.S. operations — for powertrain assembly lines. Although Carlson declined to name the company, he expressed confidence in future growth.

With more than 5,000 Coherix systems installed worldwide across 51 automotive manufacturers and 75 tier one suppliers, the company expects over 15% of its existing customer base to adopt the Coherix CARES program in the coming years.

Conclusion

As automation becomes the norm in vehicle manufacturing, maintaining the quality and precision of adhesive application is more critical than ever. Coherix CARES aims to ensure that factories equipped with high-tech inspection systems also have the support they need to deliver consistent, safe, and high-performing results. The program offers not just technical assistance, but a vital link between advanced robotics and real-world production demands, reducing error and reinforcing the safety standards that today’s vehicles require.

FAQs

What is Coherix CARES?

Coherix CARES is a subscription-based support program offering training, maintenance, and technical assistance for customers using Coherix 3D adhesive inspection systems in manufacturing.

Why is adhesive application critical in vehicle manufacturing?

Adhesives are used in critical structural and electronic components. Improper application can compromise safety features like windshield bonding and electronic sealing, putting passengers at risk.

How much does the Coherix CARES subscription cost?

The annual cost ranges from $3,000 to $5,000 per system, depending on the number of sensors and level of service required.

What kind of support does Coherix CARES provide?

The program includes maintenance, real-time technical support, and training to help factory teams optimize and sustain adhesive dispensing performance.

Who is using Coherix CARES?

Coherix recently onboarded a major Japanese automaker with U.S. operations for powertrain assembly. The company expects 15% of its customer base to subscribe in the coming years.

What makes adhesive application difficult for robots?

Unlike humans, robots require extensive programming and training to adjust to changes in materials, shapes, or conditions. Even with AI, large-scale changes often require manual intervention and retraining.