How much does welding cost?

We’re often asked “How much does welding cost” with regards to component manufacturing. There are several considerations that account for the cost of welding services, and it makes good business sense to do your due diligence when investing in outsourced welding services.

Estimating welding costs

There are three basic methods for calculating costs:

• Cost per unit
• Cost per length
• Cost per weight

Considerations for welding

Cost calculations begin by considering the right welding method and the type and size of weld joint to withstand the loads that the weldment must bear. Another factor is the purity of the weld. Does it need to be performed in a cleanroom? If so, the best choice is likely orbital gas tungsten arc welding a.k.a. GTAW or TIG, known as one of the cleanest welding methods. 

We have expert journeyperson welders, but TIG welding is still a time-consuming process. Time is generally the most expensive factor to consider when calculating welding costs. However, Axenics’ skilled welders are gifted at finding ways to be efficient while not sacrificing quality, ultimately lowering the overall cost.

For example, because we get it right the first time, there is rarely the need to repair and/or rework defective welds.

Time factors in welding services

• Preparing joints
• Preparing materials to be welded (such as removing oils, blasting, etc.)
• Assembling joints
• Preheating joints when necessary
• Tack-up
• Positioning
• Welding (The actual welding time varies depending on a manual or machined process.)
• Removing slag when necessary
• Removing splatter
• Inspecting welds and joints
• Changing electrodes
• Moving welders from one location to another
• Changing welding machine settings
• Repairing/reworking defective welds

Orbital (machine) welding is known as the purest, cleanest welding process; it is also an economical choice for those requiring weldment perfection. It’s a fast, repeatable process, and may be the ideal solution for your next project. 

Ask the list of questions below to determine whether your project would benefit from orbital welding versus other welding or fitting options. These questions take time and cost factors into consideration to offer you the best-possible quote:

• What type of material is already being used in the existing project? Does the material need to remain the same?
• What is the size and diameter of the material to be welded?
• How many fittings are needed to complete this project?
• How much space is required between weldments and fittings?
• What kind of material finishing is needed?
• Does Axenics have the right head for the orbital welding machine in-house or will we need to purchase and/or have one designed?
• If the right head is not currently available, what is the cost to purchase the needed head or produce a custom head for the machine?

The type of materials also plays into the cost of welding. We weld on a variety of metals and thermoplastics, depending on the project requirements. Axenics’ longtime raw material vendors give us fair pricing, and any money saved on raw materials gets passed on to our customers.

Welding equipment and materials costs may include:

• Shielding materials
• Electrodes
• Electric power use
• Fuel gas used for preheating
• Type of alloys/thermoplastics being welded
• Maintenance of necessary equipment

We’ll breakdown the costs of welding services for you, so you have a clear understanding of where your money goes. Keep in mind, when you work with expert component manufacturers, you’re not spending money on training, costly machines and manufacturing space. We handle that for you in-house. 

Understanding the Cost to Weld

Whether you’re a small business or a large-scale manufacturer, understanding the factors influencing welding costs helps you make informed decisions and optimize your investment. At Axenics, we aim to provide transparent, efficient, and high-quality welding solutions tailored to your needs.

Factors Influencing Welding Costs

Welding Method

The chosen welding method significantly impacts cost. Processes like TIG (GTAW) or orbital welding are clean and precise, making them ideal for high-purity applications but can be more time-intensive compared to MIG or stick welding. While TIG welding excels in quality, it requires skilled technicians and more time, which adds to the overall cost.

Material Type

The type of material plays a vital role in cost determination. Metals like stainless steel, aluminum, and exotic alloys often require specialized welding techniques, while thermoplastics have their own unique considerations. Rare or difficult-to-source materials may add to the cost.

Material Preparation and Finishing

Before welding begins, materials must be prepped, which may involve cleaning, blasting, or preheating. After welding, additional finishing steps such as slag removal, splatter cleanup, or polishing are often required. Each of these steps impacts the overall cost.

Project Scale and Complexity

Larger projects or those requiring intricate weld joints, specific diameters, or tight tolerances may necessitate more time, advanced tooling, or even custom equipment, which increases costs.

Cleanroom Requirements

If your project demands cleanroom welding, such as in the medical, semiconductor, or aerospace industries, costs may rise due to the additional environmental controls and equipment needed to ensure purity.

Why Time is a Major Cost Factor

Welding isn’t just about the time spent joining materials. Several time-intensive steps contribute to the final cost, including:

• Joint preparation (cleaning, aligning, and preheating)
• Positioning and tack-up for stability during welding
• Inspection to ensure quality and integrity of the weld
• Post-weld finishing, such as splatter or slag removal

Automated processes like orbital welding help streamline these steps, offering a faster, repeatable, and cost-effective solution for projects requiring perfection.

Cost-Saving Strategies with Axenics

At Axenics, we focus on efficiency without compromising quality, helping to lower your overall welding costs:

Expertise in Precision Welding

Our skilled technicians minimize errors and rework by getting it right the first time, saving time and materials.

Bulk Material Sourcing

We leverage our longstanding relationships with raw material vendors to secure competitive pricing, passing those savings to you.

In-House Capabilities

By keeping the entire process in-house, including welding, testing, and finishing, we eliminate additional costs associated with outsourcing.

Custom Solutions

Our ability to fabricate custom welding heads or tooling ensures even the most complex projects are executed efficiently.

Transparent Cost Breakdown

When you partner with Axenics, we provide a detailed breakdown of the costs associated with your welding project, including:

• Labor costs for skilled welders
• Equipment usage, such as CNC or orbital welding machines
• Material costs, including electrodes, shielding gases, and base materials
• Maintenance and consumables required for welding

This transparency allows you to understand where your investment is going and ensures there are no surprises.

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