What is the cost of carbon steel welding?

Welding carbon steel can be cost-effective or costly—depending on how smartly you choose your process. If you're still using outdated welding methods, you're likely paying more than you should.

The cost of carbon steel welding depends on method, labor, and material efficiency. Laser welding, especially with machines from Kirin Laser, often offers the lowest total cost over time.

If you're pricing a welding job or comparing machines, don't just look at the purchase price. You need to factor in rework, labor, and efficiency. I’ve seen clients cut their production costs in half just by switching to laser welding.

What is the rate of welding per kg?

High filler usage, inconsistent seams, and frequent rework inflate the per-kg welding rate. Many shops don't realize this until it's too late.

With traditional methods, welding carbon steel can cost $3–$8 per kg. With laser welding, the cost often drops below $2.50 per kg thanks to higher speed and less filler material.

Why filler metal and speed matter

Most traditional welding methods, like MIG or TIG, consume significant filler metal¹ and require skilled labor. For carbon steel, this means higher cost per kg—especially on larger jobs.

Laser welding, on the other hand, is contactless and has a much smaller heat-affected zone (HAZ)². This reduces warping, lowers filler consumption, and improves first-pass yield. At Kirin Laser, we’ve seen clients go from needing 3 welders per shift to just 1 operator using an automated laser system. That alone can save $50,000+ annually.

Table: Cost comparison per kg (Carbon Steel)

Welding Method	Avg. Rate (USD/kg)	Labor Intensity	Filler Usage	Rework Frequency
TIG Welding	$5–$8	High	High	Frequent
MIG Welding	$3–$5	Medium	Medium	Moderate
Laser Welding	$1.8–$2.5	Low	Low	Rare

Clients who switched to Kirin’s laser systems report consistent, high-quality seams, especially on thin to medium-gauge carbon steel. That means fewer passes, fewer mistakes, and a much lower cost per kg.

How do you calculate welding cost?

Many shops calculate cost by adding up filler, labor hours, and equipment depreciation. But that method misses hidden costs.

To calculate welding cost accurately, you must include filler metal, labor rate per hour, time per joint, equipment wear, and rework. Laser welding lowers all of these.

Key variables in welding cost

Let’s break it down:

• Filler material (kg/job)³: TIG might need 0.5–1 kg per joint. Laser might need zero.
• Labor (hourly rate × time/job)⁴: Laser welding is 2–4× faster.
• Rework (percentage of failed welds)⁵: Traditional welding might fail 10–15% of the time. Laser welds often pass first inspection.
• Power consumption & gas usage: Laser systems from Kirin are highly efficient and use minimal shielding gas.

Sample Calculation

Assume a job involves 100 carbon steel parts, each requiring a 10 cm weld.

Cost Component	Traditional Welding	Kirin Laser Welding
Filler Metal (kg)	6 kg × $8 = $48	1 kg × $8 = $8
Labor (10 hrs × $40)	$400	4 hrs × $40 = $160
Rework (15% × $300 job)	$45	$0
Total	$493	$168

The numbers speak for themselves. Laser welding isn’t just faster—it makes cost control easier.

What are the costs of welding?

Some clients ask me, “Isn’t a laser welding machine expensive?” I always say—think beyond the upfront cost.

Welding cost includes equipment, labor, filler, rework, energy, and maintenance. Laser welding machines reduce nearly all of these and deliver better long-term ROI.

Where the money goes

Most carbon steel welding costs fall into four buckets:

1. Labor

Manual welding can eat up 60–70% of total cost, especially in markets with high wages. Laser welding⁶ requires fewer operators and enables automation.

2. Filler metal

Traditional processes often overuse filler. Laser welds are narrower and deeper—requiring less filler or none at all.

3. Rework

Bad welds cost money. One client had a 20% rework rate on their carbon steel exhaust manifolds. After switching to Kirin’s fiber laser welding, rework dropped to under 2%.

4. Energy and maintenance

CO2 welding uses more gas and power. MIG guns and TIG torches degrade fast. Kirin’s laser heads have longer lifespans, fewer moving parts, and lower maintenance costs.

Table: Total cost breakdown (per 100 parts, USD)

Component	MIG Welding	Laser Welding
Labor	$400	$160
Filler	$50	$10
Rework	$60	$5
Maintenance	$40	$20
Total	$550	$195

Cost isn’t just about price per machine. It’s about operational savings and production flow. That’s where laser welding wins.

Which welding is cheaper?

When clients compare methods, they usually mean "cheapest to operate," not “cheapest to buy.”

Laser welding has a higher upfront cost, but it's cheaper in the long run due to lower labor, less filler use, and minimal rework.

Don’t confuse price with cost

Initial machine cost might look like this:

• MIG Welder: $2,000–$4,000
• TIG Welder: $3,000–$6,000
• Laser Welder: $2,000–$8,000⁷

But now look at this:

• MIG: needs skilled welder, lots of rework
• TIG: slow, high heat input, filler-heavy
• Laser: fast, clean, one operator can manage⁸

One of my clients—a mid-sized metal fab shop—was nervous about buying their first Kirin fiber laser welder. But they quickly saw that one laser machine replaced three TIG stations. Their operator training went from weeks to hours. And they now complete monthly jobs in 60% of the time.

ROI Timeline

Welding Method	Upfront Cost	Monthly Cost	ROI Timeline9
MIG	$3,000	$2,500	6+ months
TIG	$5,000	$2,800	8+ months
Laser	$20,000	$800	<5 months

If you're welding carbon steel in volume, you can't afford not to consider laser.

Conclusion

Welding carbon steel doesn’t have to be expensive—if you’re using the right tools. Laser welding machines¹⁰ from Kirin Laser offer a smarter, more cost-effective approach. They cut down on filler, speed up production, and nearly eliminate rework. Whether you’re quoting jobs or scaling up, investing in laser is not just a technical upgrade—it’s a business advantage.