Manual Welding

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Overview

Manual welding is the foundation of custom metal fabrication. When parts are complex, low volume, or frequently changing, skilled welders are often the best way to achieve strong, reliable welds and high-quality finished assemblies.

 

Our manual welding and fabrication team handles everything from one-off weldments and custom frames to short-run brackets, repairs, and assemblies that are not ideal for full automation. Through decades of experience, craftsmanship, and problem solving, our manual weldments meet high standards for quality, purity, and precision.

Advanced expertise & equipment

As a metal fabrication company, we combine skilled welders with proven welding processes and equipment to deliver consistent manual welding results.

 

Our manual welding capabilities include:

  • Gas metal arc welding (MIG) for efficient structural and production welds
  • Gas tungsten arc welding (TIG) for precise, clean welds and thinner materials
  • Resistance spot welding (RSW) for sheet and thin-gauge components
  • Stud welding where fast, repeatable attachment points are needed
  • Manual welding of stainless steel, aluminum, and carbon/mild steel
  • Integration with laser cutting, forming, machining, abrasive blasting, and powder coating

     

Our weldments are inspected and tested to help ensure quality, and our manual welding team is supported by modern equipment and fixturing to get the most out of each process.

We know the power of quality.

We synchronize our precision metal work with the highest quality of customer service, while using state-of-the-art technologies that provide customized metal fabrication solutions to fulfill our customer needs.

High-quality, cost-effective projects
on the industry's shortest lead times.

Made in Missouri,
Projects across the world.

We are pleased to announce that we are a part of the Made in Missouri USA Program sponsored by the Missouri Association of Manufacturers and the Missouri Buy MO Program, sponsored by the Office of the Governor Mike Kehoe. Both Programs are designed to showcase and support all the incredible and unique products made by Missouri manufactures and business.

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Ready to get started with a project?

We respond quickly with clear pricing, lead times, and any recommendations that could improve cost, manufacturability, or performance.

Frequently asked questions

What is manual welding?

Manual welding is welding performed by skilled welders who control the torch, gun, or electrode by hand rather than using a welding robot. In manual welding, the welder makes real-time decisions about torch angle, travel speed, and bead placement to adapt to part geometry and fit-up. Manual welding is ideal for prototypes, complex weldments, and lower-volume work where flexibility is critical.

Manual welding is often the best choice when:

  • Parts or weldments are complex or change frequently
  • Quantities are low or variable
  • Welds are hard to access with a robotic torch
  • You need one-off or short-run custom fabrication
  • Field-fit or design changes are expected during the project

Robotic welding is typically used for high-volume, repeat parts with consistent geometry. Many programs use manual welding for early builds and complex work, with robotic welding added later for repeat components.

Manual welding at FPS includes:

  • MIG (gas metal arc welding)
  • TIG (gas tungsten arc welding)
  • Resistance spot welding (RSW)
  • Stud welding

We select the manual welding process based on material, thickness, joint design, and performance requirements.

We provide manual welding of:

  • Carbon and mild steel
  • Stainless steel
  • Aluminum

If your project calls out a specific alloy or thickness, we’ll review it and confirm fit-up and welding approach as part of the quote.

Yes. Manual welding is well suited for:

  • One-off parts and prototypes
  • Custom brackets, frames, guards, and repairs
  • Short-run and specialty weldments
  • Small or mixed-quantity production jobs

You do not need a large minimum order to work with us on manual welding.

For a manual welding quote, it helps to provide:

  • Drawings or 3D models with weld symbols and material callouts
  • Plate or tube thicknesses and overall sizes
  • Quantities and whether the job is one-time or recurring
  • Any special inspection, testing, or documentation requirements
  • Notes on follow-on processes like machining, blasting, or powder coating

The more information you share upfront, the more accurately we can estimate manual welding time and cost.

All weldments are inspected and tested to help ensure quality.

Quality in manual welding is supported by:

  • Defined welding procedures and parameter ranges
  • Skilled welders with experience in multiple processes
  • Proper joint prep and fit-up from our cutting and forming operations
  • Visual inspection and measurement of weld size and location

When you need additional documentation, such as first article approvals or weld verification, we incorporate those requirements into your manual welding quote.

Yes. We can review your design and suggest manual welding improvements such as:

  • Adjusting joint types, bevels, and weld symbols
  • Adding tabs and slots for better alignment and fit-up
  • Simplifying weld lengths or changing weld sizes where appropriate
  • Improving access for the welder and torch

These changes can reduce manual welding time, improve consistency, and make downstream processes smoother.

Many projects use a mix of manual welding and robotic welding:

  • Manual welding for prototypes, complex joints, and unique assemblies
  • Robotic welding for high-volume repeat parts
  • Manual touch-up where certain welds are not practical for automation

We can help you decide which welds are best suited for manual welding and which are candidates for robotic welding, based on design and volume.

Yes. Manual welding is often one step in a complete fabrication workflow.

We can:

  • Laser cut and form parts
  • Manually weld them into assemblies
  • Machine critical interfaces
  • Abrasive blast and powder coat finished weldments

This integrated approach keeps your project under one roof from raw material through finished product.

To get started:

  1. Send your drawings or 3D models with weld symbols and materials.
  2. Tell us your quantities and whether you expect repeat work.
  3. Note if we will be cutting, forming, or machining parts in addition to manual welding.
  4. Share any inspection, testing, or finishing requirements and your target delivery date.

We’ll respond with a manual welding quote and outline the best path from first parts to completed weldments, using the right mix of craftsmanship, process control, and supporting fabrication capabilities.