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Collaborative robots are undeniably revolutionising manufacturing, offering flexibility and productivity gains by safely working side-by-side with human operators. With global integrations continuing to rise, it’s crucial that safety standards keep pace. This year ISO 10218 received its first major update since 2011, and the biggest take away is the full incorporation of collaborative robot safety directly into the core standard. 

If you are deploying, integrating, or managing collaborative systems, ISO 10218-1:2025 and ISO 10218-2:2025 signal a major shift: cobots are no longer treated as an entirely separate category, but rather as industrial robots that must meet an even clearer, more unified set of rigorous safety requirements. The standard reflects the technological advancements and growing use of cobots, dictating a critical change in how we approach risk assessment and compliance.

But what exactly does this all mean for manufacturers looking to implement collaborative robot automation?

From Specification to Standard

Previously, the specific guidelines for collaborative robot safety were primarily detailed in a separate technical specification, ISO/TS 15066. The major change now is that the guidance from ISO/TS 15066 is now consolidated directly into the main ISO 10218 framework, with two key elements:

• ISO 10218-1:2025: Focuses on the robot manufacturer’s responsibility for the robot as a product. 
• ISO 10218-2:2025: Focuses on the system integrator’s responsibility for the complete robot cell (robot, end of arm tooling, fixtures, etc.)

This change has meant a significant philosophical shift in the move away from defining “collaborative robots” as a distinctive type of robot. The new focus is now on the Collaborative Application, which defines that safety is dependent on the specific application in which the robot is used, rather than the robot system itself. 

Collaborative robot safety is now definitively unified with the broader industrial robot safety standards. No longer a separate cobot standard, all collaborative applications must now adhere to the established, rigorous framework of ISO 10218, ensuring a higher, more consistent level of safety across the board. This update also prevents the misuses of the ‘cobot’ label, forcing integrators to conduct a thorough, application specific risk assessment, which has always been the gold standard for compliance. 

Key Areas of Expansion

As collaborative robots become commonplace across industries, and used for a variety of reasons such as machine tending, welding, pick and place or dispensing, it is clear that strong safety guidelines and better risk assessments are imperative. The move to consolidate ISO/TS 15066 into ISO 10218 ensures that as automation evolves, the safety framework keeps pace, promoting safer, more productive human-robot collaboration.

Some of the most significant changes impacting collaborative robots are: 

New Classification: Robots, including those used for collaboration, are now subject to a new classification system (often Class I and Class II), with the classification dictating the required functional safety validation rigor. Many applications previously marketed as cobots may now fall under stricter categories like Class I and require additional safety measures.

Increased Focus on Cybersecurity: Reflecting modern interconnectedness, the revised standard includes new cybersecurity requirements to protect safety functions from cyber threats, ensuring a compromised network can’t inadvertently disable safety measures. 

Enhanced Guidelines for Specific Tasks: The standard now includes clearer safety guidance for end of arm tooling (EOAT) and manual load/unload procedures, explicitly addressing hazards like dropped loads, sharp tools, and pinch points during human intervention.

Explicit Requirements: Concepts like Power and Force Limiting (PFL) and Speed and Separation Monitoring (SSM), which are essential to cageless collaboration, are now explicitly detailed with clearer limits and validation methods. Pressure testing is also now mandatory to ensure cobots force remains within legal limits. 

For those deploying cobots, the message is clear - treat collaborative applications with the same seriousness as traditional guarded cells when it comes to documentation and validation.

Compliance and Documentation

A thorough risk assessment remains the cornerstone of safe integration. For every cobot application, you must systematically: 

• Identify Hazards: Look beyond just collisions; consider tooling, setup procedures, and manual handling. If your EOAT is handling heavy parts or material with sharp edges, those must be addressed with separate risk reduction measures.
• Estimate and Evaluate Risk: Determine the severity and likelihood of harm for each hazard. 
• Implement Risk Reduction: Employ a layered approach. Combine a cobot’s inherent PFL with SSM, defined operational zones, and emergency stop functionality for maximum safety assurance.
• Validate and Verify: You must measure that the safeguards work. For PFL, this means testing collision forces with calibrated sensors to prove they stay below the accepted limits for the relevant body part. 
• Document Everything: Maintain a fully traceable risk assessment report as this document is your official audit trail for regulators and internal review. 

While a 24-month transition period is typically provided after the standard’s publication, updating your current safety protocol is non-negotiable. Requiring immediate attention, it is important you: 

• Update Your Risk Assessment: All existing collaborative robot applications must be reviewed and re-assessed against the requirements of ISO 10218:2025. Remember to focus on the application, not just the cobot itself. 
• Verify Compliance Documentation: Ensure your technical documentation confirms that you are meeting the new, stricter requirements.
• Integrate New Guidance: Implement safety guidance for EOAT and any manual load/unload procedures, which are now explicitly covered in the standard. 
• Stay Current: Safety compliance is an ongoing commitment. Schedule periodic reviews of your risk assessment, especially when tasks or environments change, to ensure you remain aligned with the latest ISO 10218 criteria.

The 2025 revisions to ISO 10218 mark a significant step towards a safer, more flexible human-robot workspace. By embracing the shift to collaborative applications and prioritising compliance, industries ensure that as automation advances, worker safety remains paramount. 

Ensure Safe Collaborative Applications with Cobots Online

By embracing the clarity and rigor introduced by the unified ISO 10218:2025 standards, you ensure your cobot deployments are not just productive, but demonstrably safe partners on the factory floor. 

If you’re new to the world of cobots or looking to expand, Cobots Online are the UK’s leading experts in collaborative robot and automation integration. We’re here to design a system that adheres strictly to the guidelines set out in ISO 10218:2025, and ensure a working environment that is both highly efficient and genuinely safe. To discuss your requirements, contact our automation team today to reap the benefits of an efficient and safe working environment.