There are many welding processes that can be used in manufacturing, but the two most popular are manual welding and robotic welding. Both have their own unique set of pros and cons, which we will explore in this blog post. Manual welding is a process that requires skill and dexterity as the welder uses hand-held tools to fuse metals together. This type of welding is often used for custom projects that require a high level of detail. Robotic welding, on the other hand, involves automation of the welding process with the use of specialized machinery. This type of welding is ideal for large projects that require mass production and high speed.  Let’s dive into the advantages and disadvantages of manual and robotic welding at a glance. 


Detail – Manual welding typically offers the benefit of greater customization and detail through handcrafted execution. 

Task Flexibility – Welders can perform a variety of welding tasks, producing variation and flexibility in what they can create for customers. 

Awareness- Humans’ cognition allows for greater consciousness of processes and the ability to address a problem as opposed to a robot that continues tasks until a malfunction occurs. 


High Quality – The automation allows greater control over and in turn, higher accuracy in the welding process. 

Repeatability – Robots can consistently weld with accuracy at higher speeds than humans, so there is increased repeatability involved with this process.

Lover Labor Costs – With robots involved, less workers are required for the welding process. This reduces overall labor costs including those associated with injury and turnover. 


Injury – Even with the proper precautions, welding can be dangerous. It inherently includes the risk of individuals being injured on the job. 

Limited consistency – Human welders cannot consistently produce an identical product or action in the way that a programmed robot can. 

Limited Efficiency – Human welders usually cannot perform with the same high speeds and accuracy when compared to robots.


Investment – A robotic welding system requires a large sum of money upfront even if it can save money in the long term (think labor costs). 

Limited Task Variation – Robots are usually programmed to execute the same function which can pose a challenge for flexibility in tasks. 

Overreliance – Full dependency on the robots can be risky if the system goes down or experiences technical difficulties. 


The process of manual welding has many advantages and disadvantages when compared to robotic welding. Manual requires skill and ability which isn’t the best option for identical replication. Robotic welding is faster and requires specialized machinery. 

At Bulldog Steel, we specialize in steel projects to suit numerous applications. Contact us today for more information on welding and all things steel-related.

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