The manufacturing and fabrication industry plays a critical role in global economic development, with welding serving as one of its most indispensable trades. However, a skilled labor shortage, particularly among welders, threatens to disrupt operations and limit growth across sectors. This growing deficit calls for immediate attention and innovative solutions to ensure the industry remains competitive and sustainable. Novarc has a hand in addressing labor issues within the industry by providing groundbreaking welding technology to fabrication shops all over the world. But it isn’t only about technology, it’s about education and embracing the art of welding while helping create more work for welders.
The Scope of the Welding Shortage
There are 771,000 estimated U.S. welding professionals, as of 2024. The American Welding Society (AWS) projects that 330,000 new welding professionals are needed by 2028 with 82,500 average welding jobs to be filled annually between 2024–2028.
This shortage is being driven by an aging workforce, fewer young workers entering trades, and increased demand across construction, automotive, energy, and infrastructure sectors. The average age of a welder in the U.S. is 55, meaning many will retire in the next decade, leaving a significant gap in skilled labor.
Simultaneously, industries are undergoing transformations due to infrastructure modernization efforts and renewable energy projects, both of which rely heavily on welding. The shortage poses operational challenges, such as increased costs and delays in project completion, potentially hindering economic progress.
Health Risks Contributing to the Shortage
A significant but often overlooked factor in the welder shortage is the health risks associated with the profession. Welding exposes workers to hazardous fumes and gases, ultraviolet (UV) radiation, and extreme heat. Prolonged exposure to welding fumes, which contain metal particles like manganese and hexavalent chromium, has been linked to respiratory diseases, lung cancer, and neurological disorders.
According to the Occupational Safety and Health Administration (OSHA), welders are 44% more likely to develop lung cancer than non-welders due to fume exposure. Additionally, long-term UV exposure can cause skin burns and increase the risk of eye injuries such as “welder’s flash,” a painful inflammation of the cornea caused by UV light.
These health risks, combined with physically demanding work conditions, deter many young workers from pursuing careers in welding. Employers are increasingly challenged to provide adequate safety measures, training, and incentives to attract and retain talent.
Impacts on Manufacturing
The welding shortage significantly impacts manufacturing efficiency and productivity. Without skilled welders, companies face delays in fabricating critical components, which can ripple through supply chains. Additionally, the increased demand for welders often leads to higher labor costs, squeezing profit margins for manufacturers. In some cases, companies resort to outsourcing, which can compromise quality and oversight.
Solutions to the Skilled Labor Crisis
Addressing the welding shortage requires a multifaceted approach:
Improving Safety Standards: Employers must invest in advanced personal protective equipment (PPE), fume extraction systems, and training programs to reduce health risks and create safer workplaces.
Promoting Vocational Training: Educational campaigns highlighting the benefits of skilled trades can help dismantle the stigma and attract younger generations. Partnerships between schools and industry organizations can create clear career pathways.
Investing in Automation: Welding automation and robotic systems offer a viable solution to fill gaps in production. While not a complete substitute for human expertise, automation can handle repetitive and precision-intensive tasks, enabling skilled welders to focus on complex projects. Here at Novac our Spool Welding Robot is helping companies address their labor issues while enabling them to complete projects on time and within budget.
Apprenticeship Programs: By combining on-the-job training with classroom instruction, apprenticeships provide a practical and effective way to develop a skilled workforce. They also offer a direct pipeline for manufacturers to build talent. The American Welding Society provides some great data and resources.
The Road Ahead
The skilled trade shortage among welders is a pressing challenge that requires industry collaboration, policy support, and cultural change. Addressing health risks, investing in education, and embracing innovation are essential steps to ensure the future of welding and manufacturing.
Welding is the backbone of modern manufacturing. Solving this shortage isn’t just about filling jobs; it’s about ensuring a safer, more resilient industry.