Innovation and Collaboration in Shipbuilding

In the world of shipbuilding, where steel meets sea and tradition challenges technology, welding remains one of the most critical and labor-intensive processes to get these massive, seaworthy vessels into the water. Yet, as the industry faces aging infrastructure, workforce shortages, and demands for increased efficiency, a new wave of innovation is reshaping how ships are built.

A transformation is being fueled by modern advancements in equipment and the adoption of welding automation. This endeavor is spearheaded by the recently established Shipbuilding CoBot Alliance (SCA), a collaborative initiative poised to redefine welding in shipbuilding through automation, standardization, and accessibility.

The Current State of Welding in Shipbuilding

Despite the scale and needs of modern shipyards, various welding operations rely on more commonly used equipment and practices. In some cases, yards use older power sources alongside voltage-sensing wire feeders and other transformer-based equipment that’s big and not easily moved around the job site. Although legacy equipment is a testament to product quality, longevity, and reliability, its continued use perpetuates costly inefficiencies.

For instance, welders often have to leave their work areas — sometimes taking 15 to 30 minutes per trip — to adjust settings, leading to downtime and reduced productivity. This is especially tricky for welders in tight spaces deep within the ship who need to maneuver through multiple pathways to reach their power source, which may be hundreds of feet from where they are. As a result, total arc-on time can be as low as 5–10%.

Another shortcoming of older equipment is weld quality. For example, if the equipment parameters are incorrect and the issue is located at the power source, a decision must be made about whether or not the trip to make a minor adjustment there is worth it. Operators often default to a make-do situation, hoping the weld meets standards but also knowing rework may be required.

From time spent visiting the power source to time spent on welding rework, all that lost time adds up and costs increase. Therefore, many shipyards are beginning to incorporate lighter, remote-controlled technologies. Remote control of the power source allows welders to adjust parameters at the weld joint, maximizing arc-on time, weld quality, and jobsite safety.

Aging equipment aside, the industry also faces a critical and deepening shortage of skilled labor. The average age of the welding workforce continues to rise, with many experienced welders nearing retirement and too few younger workers entering the trade. This generational gap is exacerbated by a cultural shift: Fewer young people are pursuing careers in the skilled trades, often due to a lack of exposure, outdated perceptions of manufacturing work, or a preference for white-collar or tech-sector jobs.

The physically demanding and complex nature of welding in shipyards compounds the problem. The work requires not only structural welding of the ship but also intricate work on HVAC systems, piping, and other internal components.

Automation Assistance

Some shipyards have begun adopting more advanced technologies to address labor and quality challenges. From automated welding tractors to fixed automation systems, incremental improvements are being made. However, a leap forward for shipbuilding lies in collaborative robotics (cobots).

Cobots are designed to work alongside human operators, enhancing productivity without replacing skilled labor. They can handle repetitive, high-volume tasks, such as welding brackets or cutting access holes, freeing experienced welders to focus on more complex, high-value work.

Alliance Aims to Make Automation in Shipbuilding Accessible

The National Shipbuilding Research Program (NSRP) supports both military and commercial shipbuilding in the United States to improve the capabilities of U.S. Navy warships and commercial ships. The SCA, launched in 2024 under the NSRP, is an initiative to accelerate the adoption of cobots in shipbuilding. The project was born out of a realization that while welding robot technology existed, the barriers to implementation — particularly the Navy’s rigorous qualification standards — were too high for most shipyards to overcome alone.

The Navy requires a Level 1 qualification for any automated welding equipment used on its ships. That qualification needs to include destructive and nondestructive examination at the serial number level for a given piece of equipment, resulting in the highest level of quality and the strictest adherence to a series of specific requirements. Based on that level of rigor, several years will have passed by the time you get a system qualified, and the initial technology tested will be almost obsolete.

The SCA has developed a standardized training and qualification pathway to solve this. Through regional centers operating in Norfolk, Va., and Marinette, Wis., welders can receive hands-on training with multiple cobot systems. Ultimately, the goal is ¥to qualify a family of machines under a single standard, allowing shipyards to adopt cobots quicker and more cost-effectively.

At both locations, shipbuilders can access the following:

• Dedicated training cells equipped with cobots from top vendors to gain hands-on experience.
• Guidance on implementing cobots in shipbuilding for repair and simple assemblies.
• Industry-recognized certification programs specific to cobot operation and welding for shipbuilding.
• Cobot weld qualification and testing for Navy and commercial use.
• Curriculum and other materials to aid in training and workforce development.

The incorporation of cobots is also a win for welders. Cobots can assume redundant, repetitive weld work, allowing Class 3 welders who are newer to the industry to continue honing their welding skills. In contrast, veteran Class 1 or Class 2 welders can be redeployed to conduct higher-value welding that’s highly tactical and detailed.

A Collaborative Model for Industrywide Change

What sets the SCA apart is its collaborative, vendor-agnostic approach. This is an industry-wide collaboration among all shipyards in which cobot manufacturers come together to create a shared ecosystem that benefits the industry. Cobot suppliers, all competitors, are putting their systems in the same space and walking away, allowing the SCA to conduct training and help interested shipyards make informed decisions about what technology they will invest in and how to get it qualified. That kind of collaboration is rare in any industry but is especially impressive — and critical — in shipbuilding.

The SCA also addresses a critical funding gap. While large shipyards often receive direct government support, smaller yards and second- or third-tier suppliers are typically left behind. The SCA aims to democratize access to automation, offering training and qualification resources to all corners of the industry.

The long-term vision includes expanding to other shipbuilding hubs across the United States, including, but not limited to, New England, San Diego, the Gulf Coast, and the Pacific Northwest. With an emphasis on standardized training, reduced qualification hurdles, and growing industry buy-in, the alliance is poised to help usher in a new era of productivity and innovation.

Welding a Smarter Future

Shipbuilding has always been a complex, labor-intensive endeavor. However, as the industry faces mounting pressures, it must evolve, with success being the adoption of cobots in the shipyards. By embracing collaboration, standardization, and innovation, the industry can build ships and a workforce ready for the future.

This article was written by Ryan O’Dell (corporate account manager for Miller Electric Mfg. LLC, Appleton, Wis.) for the American Welding Society.