Key Responsibilities and Required Skills for Tooling Welder

🎯 Role Definition

A Tooling Welder is a highly specialized skilled trades professional responsible for the repair, maintenance, and modification of critical production tooling, such as injection molds, stamping dies, and fixtures. This role is foundational to manufacturing success, as it directly impacts the quality of finished parts and the operational uptime of production lines. Using advanced, high-precision welding techniques like micro-TIG and laser welding, the Tooling Welder meticulously repairs cracks, rebuilds worn surfaces, and executes engineering changes on complex tool steel components. This position demands a unique blend of artistry, technical expertise, and a deep understanding of metallurgy to restore valuable tooling to its original specifications, often working with tolerances measured in thousandths of an inch.

📈 Career Progression

Typical Career Path

Entry Point From:

General Production Welder / Fabricator
Machinist or CNC Operator
Tool & Die Maker Apprentice

Advancement To:

Lead Tooling Welder / Team Lead
Tool Room Supervisor or Manager
Welding Engineer or Technician

Lateral Moves:

Quality Control Inspector (Weld Specialist)
Tool & Die Maker
Maintenance Technician

Core Responsibilities

Primary Functions

Perform high-precision micro-TIG (Tungsten Inert Gas) welding to repair parting lines, damaged shut-offs, and sealing surfaces on plastic injection molds and die-cast dies.
Execute intricate weld repairs on stamping dies, rebuilding worn cutting edges, forming radii, and correcting surface imperfections to ensure part conformity.
Utilize laser welding technology for extremely precise weld build-up on delicate or heat-sensitive tooling components with minimal heat-affected zones.
Analyze tooling damage and consult blueprints, sketches, and 3D models to develop an effective weld repair strategy.
Meticulously prepare tooling for welding by cleaning, grinding, and pre-heating sections as required by the material type and weld procedure.
Perform post-weld heat treatment and stress-relieving processes to ensure the stability and durability of the repaired tooling.
Skillfully grind, stone, and polish welded areas to blend seamlessly with the original tool surface, matching texture and achieving exact dimensional tolerances.
Interpret complex engineering drawings, weld symbols, and part prints to ensure all repairs and modifications align with design specifications.
Select the appropriate filler materials (welding rods) based on the base metal of the tool (e.g., P20, H13, S7 tool steels, aluminum, beryllium copper) to ensure a compatible and durable repair.
Conduct thorough quality inspections of completed welds using visual examination, dye penetrant testing, and precision measurement tools like micrometers and calipers.
Maintain and troubleshoot welding equipment, including TIG welders, laser welders, and related accessories, to ensure optimal performance and safety.
Document all weld repairs performed, including the techniques used, materials applied, and hours logged, for maintenance records and traceability.
Collaborate closely with Toolmakers, Machinists, and Engineers to diagnose tooling issues and coordinate the complete repair process from welding to final fitting.
Use overhead cranes, forklifts, and other lifting equipment to safely handle and position heavy tooling components weighing several tons.
Develop and refine welding techniques for new or challenging tool steel alloys and repair scenarios to continuously improve quality and efficiency.
Adhere strictly to all company and industry safety protocols, including the proper use of personal protective equipment (PPE) and machine guarding.

Secondary Functions

Support the tool room by assisting with the disassembly and reassembly of complex molds and dies during the repair cycle.
Provide expert feedback to the engineering and design teams on tool longevity and suggest design modifications to prevent future wear or damage.
Participate in continuous improvement initiatives and root cause analysis activities related to tooling failures and production downtime.
Assist in training and mentoring apprentice-level toolmakers or welders on the specific techniques of tool and die welding.
Manage inventory of welding consumables, such as filler rods, tungsten electrodes, and shielding gases, and reorder supplies as needed.
Contribute to the organization's data strategy and roadmap.
Collaborate with business units to translate data needs into engineering requirements.
Participate in sprint planning and agile ceremonies within the data engineering team.

Required Skills & Competencies

Hard Skills (Technical)

Expert-Level TIG Welding: Demonstrated mastery of TIG welding, especially on a micro-scale, with exceptional control over heat input and bead placement.
Blueprint and Schematic Reading: The ability to fluently read and interpret complex 2D and 3D tool and die drawings, including weld symbols and geometric dimensioning and tolerancing (GD&T).
Metallurgy Knowledge: Strong understanding of various tool steels (A2, D2, H13, P20, S7), their properties, and the appropriate pre-heating, post-heating, and filler metal selection for each.
Precision Hand Finishing: Proficiency in using hand grinders, pneumatic tools, polishing stones, and lapping compounds to finish welded surfaces to extremely tight tolerances and high-quality finishes (e.g., SPI A-1).
Metrology and Inspection: Skilled in using precision measuring instruments such as micrometers, calipers, depth gauges, and indicators to verify repairs meet dimensional specifications.
Laser Welding Operation: Experience operating and setting up laser welding systems for intricate, low-heat repair work is a significant advantage.
Overhead Crane and Rigging: Certified or proficient in the safe operation of overhead cranes and proper rigging techniques for manipulating heavy tooling.

Soft Skills

Meticulous Attention to Detail: An exceptional eye for detail is critical for identifying microscopic cracks and ensuring repaired surfaces are perfectly blended and dimensionally accurate.
Problem-Solving Ability: The capacity to analyze complex tooling damage and devise effective, lasting repair solutions.
Patience and a Steady Hand: The role requires a calm, focused disposition and excellent hand-eye coordination to perform delicate, time-consuming welding and finishing tasks.
Effective Communication: Ability to clearly communicate technical information and collaborate with engineers, machinists, and management.
Independent Work Ethic: A self-starter who can manage their workflow, prioritize tasks, and work effectively with minimal supervision.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED.
Completion of a certified welding program or a formal apprenticeship in welding or tool and die.

Preferred Education:

Associate's Degree in Welding Technology or a related field.
Journeyman Tool & Die Maker or Welder certification.

Relevant Fields of Study:

Welding Technology
Manufacturing Engineering Technology
Machine Tool Technology

Experience Requirements

Typical Experience Range: 5-15+ years

Preferred: A minimum of 5 years of hands-on experience specifically in TIG welding for the repair and maintenance of plastic injection molds and/or metal stamping dies. Experience in a high-production manufacturing or job shop tool room environment is highly desired.