Student(s): Henry Burd, Demetri Kostas, Ahmad Salem
Project: Robotic Stud Welding System Developed with Structural Steel Technologies
Advisor(s): Corey Montella
Abstract
This project presents RoboStud, a prototype robotic system designed to automate the placement and welding of shear studs. In modern bridge construction, steel shear studs are welded onto steel girders to enable composite action with the concrete deck, improving structural stiffness and load distribution. However, this construction process remains largely manual, requiring workers to weld thousands of studs in repetitive and physically demanding positions, which introduces safety risks, including fatigue and long-term musculoskeletal strain, while also limiting consistency and productivity.
Our system automates this process, yielding improvements in worker safety, weld consistency, and overall efficiency. RoboStud integrates a custom-built SCARA robotic arm with a stud welding end-effector to perform precise stud placement and welding operations. A stereo vision system enables real-time detection and localization of ferrule positions under varying environmental conditions typical of construction sites. Using this visual input, the robot plans and executes accurate positioning motions to align the welding tool with target locations. The prototype demonstrates reliable detection and positioning capabilities, establishing a foundation for future full automation of the stud welding process. The primary contribution of this work is the development of a cohesive robotic platform that combines perception, motion planning, and actuation to address a labor-intensive and safety-critical task in bridge construction.
About Henry Burd
Major: Civil and Environmental Engineering
Henry Burd is a senior majoring in computer engineering and pursuing a 4+1 Master’s in mechanical engineering at Lehigh University, with a focus on controls, robotics, and automation. For his senior capstone project, he led the design and integration of RoboStud, a custom robotic arm system for automated welding on construction sites. His interests include building and rapid prototyping of real-world robotic systems. Henry has completed three internships at Structural Steel Technologies, where he contributed to the research and development of multiple construction automation products. He designed embedded control systems, created custom PCBs, and developed software solutions, earning a patent for his contributions. Outside of academics, Henry is a member of the NCAA Division I Men’s Cross Country and Track and Field teams and enjoys playing guitar.
About Demetri Kostas
Major: Computer Science and Engineering
Demetri Kostas is a senior from Massachusetts majoring in computer science and computer engineering with a minor in neuroscience at Lehigh University. His research, conducted under Dr. Yuntao Liu, focuses on evaluating the impact of high-level synthesis (HLS) on the resilience of VLSI designs to power side-channel attacks. He has completed three internships at BAE Systems within the Electronic Systems and Warfare division, gaining experience in FPGA development, embedded systems, and hardware design. His work includes FPGA programming and simulation for laser-guided missile systems; backplane design and testing for digital channelized receiver technique generator platforms on the F-35; and circuit board verification, derating analysis, and embedded C development. Across these roles, he contributed to multiple iterations of advanced defense systems, developing strong expertise in both digital and hardware-focused engineering. Outside of academics, Demetri is Vice President of the Lehigh Disc Golf Club and enjoys skiing, mountain biking, soccer, and weightlifting.
About Ahmad Salem
Major: Electrical and Computer Engineering
Ahmad Salem is a junior from Pennsylvania studying Electrical Engineering at Lehigh University, with an expected graduation of May 2026. Last summer, he interned at Structural Steel Technologies, where he designed electrical systems for industrial construction equipment and developed a UWB-based indoor positioning system as a GPS-independent alternative for crane operations. He currently leads electronics development for RoboStud, a robotic stud welding system aimed at reducing physical strain on construction workers. He also led the design of a Wireless Power Transfer system capable of powering a TV monitor through a solid wall at roughly one meter. His academic work spans VLSI circuit design, embedded systems, and power electronics, with hands-on experience in tools like Cadence Virtuoso, LTSpice, and Ansys Maxwell. Outside of school he enjoys visiting lakes, snowboarding, and playing soccer.