“That’s How We’ve Always Done It”: Why Welding’s Old Habits Still Exist—And Why They Can’t Last
Walk into almost any welding shop, and you’ll eventually hear the phrase:
“That’s how we’ve always done it.”
It’s a simple sentence, but it carries a heavy weight in our industry. It can mean “don’t question me,” “this is safe,” or “we’ve been successful with this process, so why change?”
But here’s the problem: in welding and manufacturing, the moment we stop adapting, we stop growing. And in an industry that’s still evolving at breakneck speed, standing still isn’t safe—it’s deadly.
The Roots of the Mindset
The “always done it this way” mentality didn’t come from nowhere. Welding, fabrication, and manufacturing thrive on repeatability and consistency. If something worked last time, it’s tempting to assume it will work every time.
Add in a few more factors:
Generational teaching: Many welders learned from mentors who passed down techniques. Questioning those methods can feel like disrespect.
Fear of downtime: Shops run on deadlines. Trial and error takes time, and production managers often default to sticking with the “safe” process that doesn’t risk halting output.
Risk avoidance: Welding mistakes can be costly—or catastrophic. A tried-and-true method feels safer than venturing into new territory.
This mindset was understandable in the past. But what made sense in 1975 doesn’t hold up in 2025.
Welding’s Youth: Processes Still in Their Infancy
It’s easy to forget how young modern arc welding really is.
SMAW (stick welding) only became widespread in the early 20th century.
GMAW (MIG welding) wasn’t commercially practical until the 1940s.
GTAW (TIG welding) came into play around World War II.
Flux-cored arc welding (FCAW) only took hold in the 1950s–60s.
That means many of the processes we consider “established” are barely older than our parents or grandparents. Metallurgical science around arc welding is still advancing.
Put simply: we’re still in the early chapters of welding’s story. Acting like nothing changes is the exact opposite of the truth.
Nostalgia vs. Efficiency
I’ll be the first to admit: I love my Lincoln DC-250-MK. It’s a tank of a machine, and in my opinion, one of the best welders ever built. When I fire it up, it’s not about efficiency—it’s about nostalgia. It reminds me of the roots of the trade and the welders who came before me.
But nostalgia isn’t productivity. If I ran every job on that machine, I’d be wasting time, consumables, and money compared to modern inverters or other processes.
There’s nothing wrong with respecting the past. Let me say this louder for those in the back. There’s nothing wrong with respecting the past.
The danger is confusing nostalgia with progress. Welding is about meeting today’s requirements—not yesterday’s.
The Industry Has Already Moved On
Laser welding is here. Robotic welding cells are here. Semi-automated processes that reduce fatigue, improve deposition rates, and cut variability—they’re all here. And they’re not going anywhere.
Here’s why shops can’t afford to resist change:
Efficiency demands: Customers expect more product in less time, with tighter tolerances.
Competitive edge: Shops that adopt automation, digital WPS systems, and real-time quality monitoring will outpace those that don’t.
The truth is brutal: adapt or die.
Why the Mentality Persists
So why do shops still cling to “always done it this way”? A few reasons stick out:
Comfort zone – Welders and managers alike trust what they know, even if it’s less efficient.
Investment cost – Robots, lasers, and digital systems aren’t cheap. For smaller shops, the sticker shock can reinforce old habits.
Pride and ego – Let’s be honest: in welding culture, admitting that a new machine or process can outperform a 30-year veteran feels like surrender.
Training gaps – Even if shops buy new tech, they don’t always invest in proper training. The result? They go back to what they know.
The Way Forward: Blending Tradition and Progress
Throwing away tradition isn’t the answer. There’s value in tried-and-true processes, in the lessons we learned running beads on machines like the DC-250-MK, and in the work ethic built into “this is how I was taught.”
But tradition should be a foundation—not a ceiling.
Here’s how we move forward as an industry:
Question the habits: Just because something has “always worked” doesn’t mean it’s the best way.
Test and validate: Use codes, standards, and modern WPS development to compare processes. Data, not opinion, should decide.
Embrace change incrementally: Automation doesn’t mean firing welders—it means giving them better tools.
Respect both past and future: Run the old machines for nostalgia, but run the new ones for efficiency.
Closing Thought
The “always done it this way” mindset has its roots in pride and tradition. But welding isn’t finished growing. In fact, the processes we use today may still be considered experimental in the long timeline of metallurgy and fabrication.
If we want to thrive, not just survive, we can’t let tradition chain us down. Welding has never stood still—and neither should we.