As conflicts intensify in Ukraine and the Middle East, the spotlight turns to a pressing issue: the growing shortage of skilled workers, particularly welders, in the defense sector. This shortage threatens to hinder the West’s capacity to adequately support allies and respond effectively to global hotspots.

As the world faces increasing threats and instability, the demand for defense equipment has surged. NATO allies, for example, have seen a substantial rise in defense expenditures, with a notable focus on equipment procurement.

However, this increased demand clashes with a stark reality: there are simply not enough skilled workers to meet the growing needs of the defense industry. A major contributor to this crisis is the critical need for welding expertise, a skill often underestimated yet indispensable in defense manufacturing.

This gap between demand and supply not only impacts the production of vital defense equipment but also poses a significant risk to Western nations’ ability to effectively support Ukraine in their conflict with Russia and to respond to rising tensions in the Middle East.

The Unsung Heroes of Defense Manufacturing 

Welding, often perceived as a mere manual task, is in fact a highly specialized and technical skill pivotal to the production of critical defense equipment.

This process involves more than just joining metal parts; it requires a deep understanding of materials, precision, and techniques that ensure the safety and reliability of military hardware.

From combat vehicles to aircraft, ships, ammunition and weaponry, manual welding is still an integral part of manufacturing these complex systems.

For example, in a 2024 Financial Times article, Elisabeth Braw quotes David Chour, CEO of the Czechoslovak Group (CSG), responsible for manufacturing the 155mm Artillery shells used by Nato (and Ukraine), on the need for expert craftsmanship during the manufacturing process:

“‘At the end of the process of making artillery shells, when you have to feel the explosive inside the shell, there’s nothing automatic about that,’ the European executive told me. ‘There are parts of planes that are still handcrafted. There are many automated processes, but defense manufacturing relies on expert workers’”

BRAW

Welders in the defense industry are responsible for tasks that demand a high degree of accuracy and proficiency. They work with a variety of materials, each with its own properties and challenges, and are required to perform under stringent quality control standards. As is evidenced by the American Welding Society codes and standards list, detailing 350 standards for welding practices and procedures, specific to industry, welding type, and materials being welded among others.  

The welding techniques used in defense manufacturing, such as Tungsten Inert Gas (TIG) welding, Metal Inert Gas (MIG) welding, and shielded metal arc welding, are complex and require significant skill and experience to execute effectively. 

The role of welders extends beyond merely fabrication. They are responsible for ensuring the structural integrity and durability of equipment that will be used in harsh and demanding environments. 

This includes understanding the stresses and strains that materials will undergo and applying welding techniques that can withstand these conditions. The work of welders is therefore crucial not only in the production of defense equipment but also in ensuring the safety of those who operate it. 

Defense Manufacturing Demand Soars, but Supply Falters 

The defense industry is currently facing a paradoxical situation: while the demand for military equipment has skyrocketed due to increased geopolitical tensions, the supply of skilled workers essential for manufacturing this equipment is woefully inadequate. 

This disparity is particularly acute in the field of welding, where a shortage of qualified professionals is impeding the production capabilities of defense contractors. 

According to NATO’s Defence Expenditure of NATO Countries (2014-2023) July 2023 press release, across NATO members the proportion of total defense expenditure for “Equipment” rose from an average of 21.9% in 2020, to 30.4% in 2023 (13). A sharp 38% increase. 

Alternatively, spending on “Personnel” dropped from 51% in 2020 to 39.8% in 2023. 

Bulgaria had the most noticeable rise in proportional equipment expenditure, seeing a stunning 316% increase when compared to 2020. 

This is more than likely due to its role in supplying soviet-caliber ammunition to Ukraine, a critical aspect to Ukraine’s defensive efforts, filling in for the sluggish ramp up in production from NATO’s largest donors such as the UK and United States (Volkmann-Schluck, “Bulgaria to the Rescue”). 

However, this escalation in defense spending is not being matched by the availability of skilled workers required to produce this equipment.

Defense manufacturers across the globe are struggling to find enough welders, electricians, and other technical professionals. This shortage is not just a theoretical concern but a serious risk to major defense projects. 

Looming Talent Gap Threatens Defense Capabilities 

The defense industry’s struggle to recruit skilled workers, particularly welders when compared to other industries, is exacerbated by a widening generational gap and a sluggish reaction to the changing dynamics and career preferences of younger generations.

Joseph Clark of DOD News, quoting Keith DeVries, MD of manufacturing technology for the Office of the Secretary of Defense sums this issue up well: “The defense industry is tapping into the same pool as the commercial industry,” he said. “If Caterpillar or Toyota were to hire 1,000 assemblers or 2,000 welders for their commercial demands, that impacts the defense industry’s ability to tap into the same skill sets.” (Clark).

As older, experienced workers exit the workforce, they leave behind a void that is not easily filled. These individuals possess years of accumulated knowledge and expertise, particularly in specialized skills like welding. The knowledge transfer from seasoned workers to newcomers is a critical process.

According to the U.S. Bureau of Labor Statistics Job Openings and Labor Turnover Survey (JOLTS), the “Net Employment Change” (Hires / People Leaving Jobs) for the manufacturing sector sits at 1.06 since 2021, indicating a sector employment growth of 0.06%, which is lower than the national combined industry sector rate of 1.08 or 0.08%.

More worryingly, the survey shows that since the Russian invasion of Ukraine in early 2022, the net employment change in the manufacturing industry has fallen from 0.09% to just 0.02%, steep when compared to the national average which saw 0.07% in 2021 to 0.06%.

As discussed in ATS’s How has the Coronavirus Impacted Manufacturing, while the manufacturing sector saw major disruption due to the pandemic, with reported issues being delivery delays, increased costs, uncertainty, and shifts in demand, it’s worrying that an increasingly critical sector saw not just stagnation, but contraction.

Running parallel to the departure of older, experienced workers is the difficulty of attracting millennials and the younger workforce to careers in welding and other technical trades in order to fill this gap. 

In a 2023 National Defence Magazine article, Stew Magnuson quotes Andy Voelker, associate of the global management consulting firm McKinsey & Company, on a particular challenge faced by employers in the aerospace and defense sectors: “There is a “gray to green” workforce transition. There is a retirement bubble on the horizon for both manufacturing jobs and engineers, with one out of every three employees in the sector nearing a “retirement window.” Voelker continues: “We also know that the greener talent has fundamentally different expectations [of work life], so this presents a real challenge as we think about building the next generation of leaders,” (Magnuson). 

The defense industry is finding it challenging to appeal to younger generations, who often have different career aspirations and are drawn to industries perceived as more modern or technologically advanced. 

This disconnect creates a recruitment challenge for defense manufacturers, who require a steady influx of new talent to sustain their operations.

This issue becomes clear when looking at the U.S. Bureau of Labor Statistics Job Openings and Labor Turnover Survey (JOLTS) figures from 2021 to 2023, and calculating for “Job Openings to Hire %” (Jobs / Hires).

This calculation shows that the national combined sector sits at an average of 62%, meaning 62% of positions are being met with a hire, an issue in its own right, but the picture only gets worse when you compare the 57% “Job Openings to Hire %” for the same period in the manufacturing industry.

The problem will require a multi-faceted approach. It will need to involve efforts in not only attracting new talent, but also in providing the necessary training and mentorship to develop their skills, an aspect of their career development made harder each year with the loss of experienced workers. 

It will also require efforts to “redefine what being a skilled tradesperson looks like” (CWB Welding Foundation), changing the perception of careers in welding and similar trades, highlighting the advanced technology, critical importance, and career opportunities available in the industry.

Global Impact of Talent Shortage

The shortage of skilled welders, among other technical workers, in the defense industry is not just a localized problem; it has far-reaching global implications.

This deficit is affecting the production capacity of defense manufacturers around the world, directly impacting the ability of countries to adequately arm themselves and support allies in conflict zones.

In Raytheon Technologies’ Notice of 2023 Annual Meeting of Shareowners and Proxy Statement, the issue of staff shortages is a consistently mentioned issue of great effect and importance. (United States Securities And Exchange Commission, May 2, 2023).

This staff shortage, combined with “persistent global supply chain pressures” (FRB NY, 2024), illuminates the reasons for the sector’s subsequent slow reaction to increased demand.

The impact of this labor shortage is particularly acute in the context of the ongoing conflict in Ukraine and beyond. Western countries are under pressure to increase their support, including the delivery of military equipment and ammunition. 

However, the scarcity of skilled workers in the defense industry is contributing to delays in fulfilling these needs.

The delay in fulfilling these orders could have serious consequences, as geopolitical tensions continue to rise.

How The Sector Aims to Rebuild the Defense Workforce

In response to the critical shortage of skilled workers in the defense industry, various initiatives and strategies are being implemented to both attract and train new talent, and to mitigate the consequences of these shortages with improvements to productivity via new technology.

While technology seems to be advancing at a dazzling rate in all aspects of our lives, when looking specifically at manufacturing and the defense sector, the sentiment seems to be on acquiring and retaining human talent over new productivity-improving technology.

In EY’s 2022 Aerospace and Defense Workforce Study, representatives across various market-leading A&D companies were asked: “Which of the following are critical to a sustainable future of work for your organization?” An overwhelming 81% of respondents selected: “Developing a workforce strategy and plan to ensure necessary talent and skills to match future business needs” (“How do you reshape”, 25). 

A manifestation of this effort can be found In the United States, where defense manufacturers are taking proactive steps to attract young talent by targeting both high-school and university career fairs.

Prominent industry names such as Raytheon, Northrop Grumman, Boeing, and Lockheed Martin have stepped up their presence nation-wide at career fairs, prompting discussions amongst students in dedicated forums. 

In a dedicated reddit forum for University of Michigan attendees, students discussed the phenomenon, with many pointing out the reason is likely staffing shortages and rising military tensions, highlighting the fact these industry struggles have sadly been so prolonged that it’s become common knowledge.

There has also been a shift in retention strategies amongst employers, who are improving not only pay, but also flexibility and training/ upskilling opportunities for their manufacturing workforces.

According to Deloitte’s 2024 Manufacturing Industry Outlook, as of this year “46.8% of manufacturers offer flexible scheduling, including remote work, compressed workweeks, and shift swapping”, and that this, combined with the “4% increase in average hourly earnings between Q1 FY2022 and Q1 FY2023”, saw a “19% decrease in voluntary separations.”(Coykendall, Hardin and Morehouse).

To address the knowledge gap which comes from older more experienced workers leaving without passing on their knowledge, in the same article, Deloitte details that many manufacturers are instituting “alumni programs” to keep retired works more engaged with the business and industry as a whole, forming a community of passionate professionals with the ability to influence and communicate with the new generation of workers.

There has been a push for integrating new technologies to assist with training and the transfer of knowledge to newer workers. One such example is the increasing usage of VR in training. 

Companies like Immerse, who work with big manufacturing names like Nestle, offer what they call “immersive learning” for a range of crucial aspects of manufacturing training. They offer out-of-the-box VR training courses on health and safety and hazard awareness, and also offer assistance in creating custom content specifically for its customers. 

Immerse claims that through its “immersive learning” their manufacturing customers saw a 50% decrease in training time and a 75% improvement to information recall. (immerse.io)

A Potential Golden Age for Aspiring Welders 

While this glimpse into the defense industry’s struggle with a critical shortage of skilled welders – a gap that threatens to hinder global security and exacerbate geopolitical tensions – paints a stark picture, amidst this challenge lies a unique opportunity for aspiring welders.

Recognizing the talent crunch, the industry is actively bridging the gap by engaging a new generation of welders, highlighting the modern, technologically advanced aspects of welding careers, promising an exciting and dynamic work environment.

The combination of rising defense expenditures, an aging workforce, and industry-wide demand for skilled welders creates a potential golden age for those who choose to pursue a career in welding, promising high job security and competitive salaries for those who enter the field. 

So, if you’re looking for a career that is challenging, impactful, and increasingly valued, consider exploring welding in defense manufacturing.