Robotic continuous ultrasonic welding (cUSW) is a promising technique for joining carbon fiber-reinforced thermoplastics (CFR-TP), offering high efficiency and fast processing times. However, maintaining weld quality and process robustness presents significant challenges. The characteristics of the weld such as joint strength and long-term performance are heavily influenced by key parameters during both heat generation and consolidation phases. Understanding the interactions between the robotic system and the ultrasonic welding process is essential, as they directly impact the quality and consistency of the weld. The robot must precisely control the sonotrode’s movement in the heat generation phase to maintain constant force, trajectory accuracy, and speed uniformity, ensuring efficient energy transfer and uniform melting. During consolidation, both speed and force are critical, controlling the heat dissipation to bring the interface temperature below the crystallization point, preventing defects. To address these challenges, real-time monitoring of key process parameters is essential. Advanced sensor integration and data-driven control strategies enable dynamic adjustments to optimize welding conditions and prevent defects. This paper explores the challenges associated with robotic continuous ultrasonic welding of CFR-TP and discusses monitoring techniques and control strategies to enhance weld consistency and process reliability.