Lead Robotics Controls Engineer – Custom Systems Integration

Impact Recruitment Ltd; Waukesha (WI); On-site; USD 108,000 - 132,000; Full time

Job summary

Impact Recruitment Ltd is seeking a Lead Robotics Controls Engineer for a direct-hire role in the Waukesha, WI area. You will design, program, and integrate custom automation systems, leading projects from simulation to on-site commissioning.

You’ll apply ABB RobotStudio and RAPID extensively, with PLC integration using Studio 5000/RSLogix, while traveling up to 30% worldwide for client deployments.

Qualifications

• 5+ years programming, commissioning, and configuring ABB robotic systems in automation environments.
• Proficient with ABB RobotStudio for virtual cells and RAPID coding.
• 2+ years PLC integration with Allen-Bradley (Studio 5000/RSLogix).
• Strong hardware/safety knowledge for servo drives and vision networks.
• Bachelor’s degree in Automation, Electrical, or Mechanical Eng preferred.
• Global mobility with travel up to 30% worldwide; US passport ready.

Responsibilities

• Develop, simulate, and optimize complex multi-axis robotic programs with ABB RobotStudio and RAPID.
• Lead automation projects from concept through shop-floor assembly and commissioning.
• Configure robot setups and fieldbus networking with PLC controllers.
• Troubleshoot robotic logic, motion faults, bottlenecks, and communication errors.
• Collaborate with mechanical/controls teams on EOAT, vision, and safety params.
• Travel up to 30% for installations, testing, and handoffs to customers.
• Create detailed system documentation and operator manuals.

Skills

ABB RobotStudio

RAPID coding

Studio 5000/RSLogix

Allen-Bradley PLCs

Robotics integration

Servo drives

Industrial vision nets

Education

Bachelor’s degree in Automation, Electrical, or Mechanical Eng

Job description

Job Order ID: 4718

Employment Type: Permanent

Salary: $120000/Yr

Web Publication Date: 7/23/2026 12:00:00 AM

Job Location: Waukesha, WI 53186

Job Function:

Lead Robotics Controls Engineer – Custom Systems Integration

Up to $120,000 Base Salary + Dynamic Bonuses • Waukesha, WI Area • 1st Shift • Onsite / Up to 30% Travel • Direct-Hire

• PROJECT VARIETY: Build unique, custom automated machinery and advanced robotic cells from initial simulation to floor commissioning—no repetitive factory lines
• TECHNICAL DEPTH: 5+ years of dedicated, hands-on experience designing, programming, and integrating custom industrial automation systems and robotics
• ROBOTICS & CONTROLS: Mastery of ABB RobotStudio and native RAPID coding, coupled with 2+ years interfacing robotic cells with Allen-Bradley PLCs (Studio 5000 / RSLogix)
• TRAVEL & MOBILITY: Up to 30% domestic and international travel for high-visibility client installations, site commissioning, and acceptance testing (Valid U.S. Passport required)
• REQUIREMENTS: US Citizen or Green Card holder residing within a comfortable daily driving radius of the Waukesha, WI area

If you are an elite robotics engineer feeling stifled by rigid corporate structures or repetitive plant maintenance, this direct-hire engineering seat is your ticket to true technical autonomy. The employer is a certified, premier custom industrial automation systems integrator in the Waukesha area with an unyielding backlog of custom contracts spanning aerospace, medical, and consumer goods sectors.

Instead of repetitive production lines, you will design and build custom, first-of-their-kind machinery tailored to complex application requirements. Operating out of a tech-driven facility where design engineering and physical assembly live under one roof, you get the unique satisfaction of taking a project from a blank-screen 3D simulation to watching your digital code drive heavy, physical machinery right down the hall.

What You Will Be Doing (Daily Responsibilities)

• Develop, simulate, and optimize complex multi-axis robotic programs from scratch utilizing ABB RobotStudio and RAPID code architectures.
• Manage automation projects across the full lifecycle, from initial concept and virtual simulation through physical shop-floor assembly, debugging, and final field commissioning.
• Configure initial robot setups and communications, mapping payload profiles and establishing fieldbus networks (EtherNet/IP, PROFINET) with PLC controllers.
• Serve as the lead technical SME to troubleshoot intricate robotic logic, motion control faults, cycle-time bottlenecks, and communication errors.
• Partner cross-functionally with mechanical and controls teams to design custom End-of-Arm Tooling (EOAT), vision guidance profiles, and RIA/ISO machine safety parameters.
• Travel up to 30% domestically and internationally to lead cell installations, execute client acceptance testing, and provide high-level customer handoffs.
• Author meticulous technical documentation, system logic schematics, and client-facing operating manuals.

What We Are Looking For (Requirements & Qualifications)

• 5+ years of verifiable experience programming, commissioning, and configuring ABB robotic systems within custom industrial automation or systems integration environments.
• Proven capability using ABB RobotStudio to build virtual workcells, execute reachability studies, and write native RAPID code.
• 2+ years of practical PLC integration experience establishing data handshakes with Allen-Bradley platforms (Studio 5000 / RSLogix).
• Hardware & Safety Competency: Heavy technical familiarity with servo drive systems, industrial vision networks (Cognex, Keyence), and machine safety standards.
• Degree & Experience Balance: Bachelor’s degree in Automation, Electrical, or Mechanical Engineering preferred (deep, hands-on field integration expertise will be strongly considered in lieu of a degree).
• Global Mobility: Valid U.S. Passport and complete readiness to travel up to 30% worldwide for deployment and commissioning.
• Local Proximity: Residing within a dependable, daily driving radius of the Waukesha, WI area.

Note: This description omits application instructions and recruiter contact blocks to comply with refinement requirements.