Recently, the metal fab industry has come to a crossroads where embracing technological advancements is not just an option but a necessity for maintaining competitiveness. Smart manufacturing, a data-driven approach to production, integrates cutting-edge technology, real-time analytics, and enhanced automation to bring your shop up to speed.

As a company supplying this industry for over 100 years, we've seen firsthand how leveraging these innovations can truly transform your operations. One of the biggest takeaways we've discovered when using these tools is that they can help pave the way for sustainable growth at your business. 
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Let's explore the best ways and options to use the tools, technologies, and strategies that drive smart manufacturing!

At the heart of smart manufacturing is the Internet of Things (IoT)—a network of connected devices that collect, share, and analyze real-time data to enhance efficiency, reduce waste, and improve decision-making. In the metal fabrication and welding industries, IoT technology is revolutionizing the way manufacturers monitor equipment, optimize processes, and maintain quality standards.

IoT (Internet of Things) devices embedded in manufacturing equipment generate real-time data that can be analyzed for all sorts of things, such as unnecessary waste and preventative maintenance. Hypertherm's cartridge reader app is a great example of this in practice- it allows you to track the life of your cartridge, as well as cut quality, starts, transfers, and arc-on time. It also provides a cartridge to job compatibility analysis and can make recommendations for a better cut experience! Plus the Training and Resource Center lets the user review tips and brush up on training. Using this approach minimizes downtime by addressing issues before they have time to escalate preventing costly disruptions, and extending the life of your equipment.

As manufacturers embrace IoT-powered solutions, they gain the ability to stay ahead of the competition by adapting to challenges, lowering costs, and delivering higher-quality products faster and more efficiently than ever before!

When it comes to welding, choosing the right method can have a significant impact on quality, efficiency, and overall production time. Traditional welding processes, like MIG and TIG, have long been the go-to choices for many industries, but lately laser welding has been a hot topic of conversation in the industry. Wondering if laser welding will replace TIG? 

While traditional processes have their place, we firmly believe that laser welding is  revolutionizing modern fabrication! Read on for a breakdown of the differences between these methods, from training to final results, and you’ll see how laser welding stands out from the crowd!

As a welding technical school, we know better than anyone that learning how to weld, and weld well, takes time and effort. When it comes to TIG welding, while useful for a variety of jobs, it demands a pretty high level of skill and significant training time to master. TIG welders need precise hand coordination to juggle the torch, filler material, and pedal controls simultaneously. Additionally the set up requires adjustments to the gas flow, electrode type, and torch angles. Even minor missteps can lead to weld defects or inconsistent results, adding more time to the process. This learning curve can delay the onboarding of new welders and significantly increase training costs.

Weld quality is another area where laser welding really stands out. TIG welding, while capable of producing high-quality welds, often struggles with issues like spatter, contamination, and uneven penetration—particularly when operated by welders with less experience. TIG welding’s reliance on the manual control of the welder means more room for human error, often leading to welds that need rework. Grinding and cleaning are common post-weld tasks that consume time and labor, driving up costs and extending the production timeline.
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MIG welding, while faster than TIG, often produces welds with more spatter and less precision, especially on thinner materials. This can lead to defects and the need for additional cleaning or rework- and those post weld tasks can add up!

Laser welding, on the other hand, produces exceptionally clean, precise welds with minimal spatter and distortion. Laser allows for consistent penetration and fusion, making the likelihood of defects significantly less. The results of laser welding often require no additional cleaning or finishing, and this reduction in rework not only saves time but also increases overall productivity, allowing teams to focus on new projects instead of reworking and fixing old ones.

Our comprehensive welding program provides our students with the skills they need to succeed on the job- our intermediate and advanced classes include certification tests that make students job-ready out of the gate! But securing a welding job requires more than technical skills—it’s about showing potential employers that you’re reliable, safe, and a good fit for their team. So here are some tips to help ensure your welding interview goes smoothly, allowing you to showcase your skills and land the job you want!

Clarity ratings provide a standardized measure of how well a welding helmet lens performs under specific conditions. You may have come across different ways of expressing these clarity ratings so let's discuss the differences. Put simply, ANSI Z87.1 standards provide guidelines specific to eye and face protection for American industries, while EN379 standards offer a more detailed breakdown of clarity ratings for auto-darkening filters.

ANSI Z87.1
Here in the U.S., the American National Standards Institute (ANSI) offers clarity rating guidelines under ANSI Z87.1. This standard is what OSHA goes by and it addresses the safety of the lens even if it is not functioning correctly or it's turned off- basically ensuring that the lens passively protects your eyes and face, no matter what. The second thing that the ANZ87.1 standard also regulates is just how much visibility you will get at each shade setting- which is measured by a light transmittance test. This standardized test measures how well you can see the welding arc through the helmet from 0-100% (0% = no visibility and 100% = naked eye). For each lens shade, there is a minimum percent of visible light allowed for top clarity, as well as a maximum percent of light that's allowed, to protect your eyes and reduce fatigue.

EN379
For certain helmets, you may also see an additional rating that is expressed like this: 1/1/1/1. This rating follows the European Standards (EN) clarity rating for Auto-Darkening Helmets. Although these are not mandatory in the U.S., they can be helpful since they do offer a simple breakdown for easy decision making. How it works is that each number corresponds to a graded scaled for four different considerations. Each category is graded from 3 (lowest) to 1 (highest), meaning the highest clarity helmet would be rated as 1/1/1/1 across all categories. These considerations are as follows:

1. Optical Distortion – How clearly you can see through the lens with no warping or bending of the image.
2. Lens Uniformity – The consistency in the quality and purity of the lens material.
3. Dark State Consistency – How consistently dark the lens is.
4. Angle Dependence – The lens’s clarity and darkening performance when looking at an arc from a sharp angle.

Helmets rated by both standards help to provide an extra level of assurance. The ANSI standard ensures safety compliance, while the EN standard measures performance specifically for optical clarity. When comparing helmets, look for lenses that meet the ANSI standard and have the lowest numbers in each category for the EN standard. 

​It seems obvious that using a helmet with excellent optical clarity will help you to produce better welds, simply because you'll be able to see what you're doing. But there are other things at play here- like your comfort and safety- that contribute to the overall experience. Poor clarity can lead to distorted vision which strains your eyes and can affect the precision of your work as well as your productivity. Distortion, in particular, can make it hard to see fine details, which are critical in tasks calling for high accuracy. Helmets with high ratings allow for better visibility in both light and dark states, which gives you better control over your weld and minimizes the potential of mistakes and subsequent rework.

Here are a few practical tips:

1. Check the Light Transmittance Levels – Choose a helmet that meets ANSI Z87.1 standards for light transmittance in both light and dark states. This ensures that the lens provides a clear view without letting harmful levels of light through.
2. Optimize Your Lighting Environment – Even the best clarity-rated helmets can benefit from adequate ambient lighting. If your workspace is dim, consider integrating additional lighting solutions to enhance visibility, either as part of the helmet or through external lighting setups.
3. Invest in High-Quality Lens Accessories – For those who use magnifying lenses, choose ANSI-certified lenses and quality cover lenses to improve clarity and prolong lens life. These accessories can make a big difference in both clarity and comfort.
4. Consider the EN Standard Ratings – If you’re comparing helmets, you'll likely come across the EN optical ratings. While not required in the U.S., these ratings can offer additional insight. Generally you'll want to look at first three categories (1/1/1/x) as they're crucial for welding, while the fourth rating tends to be less impactful because the difference is hard to notice and only applies at extreme viewing angles.

So whether you’re a professional welder or a weekend hobbyist, finding a helmet with superior clarity ratings will pay off in both the short and long term. If you're in the market for a new helmet, keeping these clarity ratings in mind will help you find the perfect balance of comfort, performance, and safety. But if you're not feeling like doing the research, don't worry, we've got you. Check out the short list below to see helmets that we firmly believe are winners when it comes to clarity and comfort!