As technology continues to reshape industries, welding has been undergoing its own quiet revolution. AI-enhanced vision systems, cobots, 3D-welding, friction welding and more are redefining craft needs, what skills remain essential and why it’s an exciting time to join the trade.
We spoke with Zachery Taylor, welding and metallurgy manager at Burns & McDonnell. His role centers on modernizing and standardizing welding technologies in both field and shop settings, promoting collaboration between construction and design teams to adopt innovative methods.
Q: How will automation, cobots and AI-driven parameter optimization change the role of human welders over the next five to 10 years? And which tasks will remain distinctly human?
Welding machines already have sensors that can read the electrical characteristics of an arc and adjust in real time. The next leap comes from pairing that data with AI-powered vision systems that interpret the weld puddle — essentially teaching machines to “see” like a welder. This combination enables adaptive control and higher consistency. These tools will help address labor shortages by allowing experienced welders to extend their careers and focus on guiding systems rather than performing every weld manually. It shifts the emphasis from physical precision to mental skill and knowledge.
With that said, automation can’t cover every scenario. The future welder’s greatest asset will be their judgment and experience, not necessarily a perfectly steady hand. Complex geometries, confined spaces and unique field conditions will always demand human adaptability. Certain welds require the flexibility and intuition of a person who can interpret the situation in real time. Automation will take over repetitive or standardized tasks, freeing welders to focus on the more intricate or unconventional work that machines can’t yet handle.
Q: Which welding methods are poised for the most growth?
Automation-driven processes will continue expanding, especially those involving AI control systems and cobots. Cobots are changing how shops approach automation: They’re mobile, collaborative and affordable. Instead of moving all the work to a fixed robotic cell, cobots bring automation to the job, opening creative possibilities in both fabrication and field applications.
Q: How will new technology and data tools change how welding quality and safety are managed?
One of the first things I heard from Ray Kowalik, former Burns & McDonnell CEO — and it's one of my favorites — is that we have a moral obligation to keep our people safe and a commitment to serve our clients with the highest quality we can produce.
I believe if we can complete a weld faster using new technology, we can reduce the time our craft professionals spend in potentially hazardous environments. That alone improves safety. These systems also create a more consistent product by reducing reliance on individual skill differences. With automation, we can normalize quality across a large workforce, meeting design and client standards more efficiently while maintaining safety as a moral duty to every worker.
Q: What skills and training will welders need most to stay ahead in the industry?
Organizations need to invest in in-house training tailored to their own technologies. Relying solely on external welding schools and the trades isn’t enough. Companies can also partner with a specific firm to train their craft with the tools they provide, emphasizing what safety measures and expectations they require. It is crucial to prepare welders for emerging tools and techniques. The goal should be to make training ongoing, collaborative and aligned with the company’s ethics.
Q: What would you tell someone considering a career in welding?
It’s a very exciting time to enter the field. I started out of curiosity, to see how welding and engineering fit together. Now, we’re seeing welding merge with AI. The opportunities are expanding rapidly and there’s a lot of room for creativity, innovation and lifelong learning. If you’re curious and willing to adapt, this field is the place for you.
