Solving the skilled welder shortage with castings

Reduce labor shortages, cut costs, and improve efficiency with castings

    The skilled welder shortage is driving up labor costs, delaying production, and creating supply chain disruptions. With an estimated 330,000 welders needed by 2028, manufacturers must rethink how they scale operations. One proven solution is transitioning from weldments to castings—reducing labor reliance while improving efficiency and cost savings.

    This shortage is already impacting key industries like construction, agriculture, and heavy machinery—leading to project delays and increased material costs. Manufacturers that rely on skilled welders face mounting challenges in meeting demand, maintaining production efficiency, and controlling expenses.

    To stay competitive, companies must explore alternative manufacturing solutions that reduce dependency on manual welding. One such solution is castings. By replacing weldments with castings, manufacturers can reduce labor bottlenecks, improve product consistency, and optimize production costs.

      Man welding

      Why is there a shortage of skilled welders?

      The welder shortage is driven by several key factors.

      The average age of a welder in the U.S. is 55, with many nearing retirement. As experienced professionals exit the workforce, the talent pool continues to shrink.

      Fewer young individuals are pursuing welding careers. This trend is influenced by limited awareness of opportunities in skilled trades and the growing emphasis on four-year college degrees.

      Rapid growth in industries such as construction, automotive, and infrastructure has intensified the demand for skilled welders, exacerbating the gap between supply and demand.

      The impact on manufacturing

      The shortage of welders poses significant challenges for manufacturers.

      Insufficient staffing can result in missed deadlines, leading to project delays and dissatisfied customers.

      With fewer skilled welders available, manufacturers may face rising labor costs due to overtime and competitive wages.

      Inexperienced or overworked welders may produce inconsistent welds, compromising product integrity and reliability.

      These challenges underscore the need for manufacturers to rethink their production strategies and adopt alternatives that reduce reliance on manual welding.

      How castings solve the challenges of the welder shortage

      Switching from weldments to castings offers a strategic way to mitigate the impact of the welder shortage. Here’s how.

      By converting weldments to castings, manufacturers can significantly reduce their reliance on manual welding. Castings are produced using automated processes, eliminating many of the labor-intensive steps associated with welding.

      Castings streamline the production process by consolidating multiple components into a single piece. This not only saves time but also ensures consistent quality across production runs.

      With fewer labor requirements and reduced material waste, castings provide a cost-effective alternative to traditional weldments. Manufacturers can reallocate resources to focus on higher-value activities.

      Castings eliminate the variability inherent in manual welding. They are produced using precise molds, ensuring uniformity and reliability in every part.

        Why choose Milson Foundry?

        At Milson, we live to make things better. Our team helps manufacturers tackle challenges like the skilled welder shortage by providing engineered castings that are assembly-ready and built for performance.

        We work closely with our clients to:

        — Analyze existing weldments to identify cost-saving opportunities.

        — Optimize designs for casting to improve efficiency and durability.

        — Deliver tailored casting solutions that integrate seamlessly into production.

        Ready to make the switch?

        Looking for a cost-effective, scalable alternative to weldments? Milson Foundry provides precision-engineered castings that arrive assembly-ready—reducing labor costs, improving consistency, and increasing production efficiency. Contact us today to learn how castings can transform your manufacturing process.

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        FAQ

        How does converting weldments to castings help with the welder shortage?
        Castings eliminate the need for manual welding by automating much of the production process, reducing reliance on skilled welders.

        What industries benefit from switching to castings?
        Industries such as construction, agriculture, and heavy machinery often see the greatest benefits from transitioning to castings.

        What is the ROI of converting weldments to castings?
        While specific savings depend on the application, manufacturers typically experience reduced labor costs, improved efficiency, and fewer production delays.

        How does Milson Foundry ensure quality in castings?
        Milson Foundry uses precise molds and rigorous quality control processes to deliver reliable, high-performance components.