Business Details
28 Years
experience
Expert Welding Process Control & Training Solutions
With over six decades of hands-on experience in the welding industry, Weld Reality was established in 1998 to address critical gaps in global weld process control and training. Our founder, Ed Em Craig, has worked across 13 countries, delivering process improvements for manual, automated, and robotic welding systems at hundreds of companies, including Fortune 500 firms. We specialize in GMA, FCA, and TIP TIG welding processes, focusing on eliminating rework, reducing costs, and enhancing productivity through proprietary training programs. Our expertise stems from decades of solving real-world challenges in automotive, aerospace, shipbuilding, and nuclear industries, where weve pioneered methodologies now used by global leaders like Dana and Caterpillar.We emphasize practical, no-nonsense solutions over sales-driven approaches, ensuring clients gain actionable expertise in weld process ownership, cost analysis, and quality optimization. Our work with organizations such as Commonwealth Fusion Systems and NASA underscores our commitment to advancing welding technology and education.
Services
Weld Process Training
Robot Weld Optimization
TIP TIG Training
Weld Cost Analysis
Flux Cored Process Consulting
Weld Quality Audits
Welder Certification Programs
Weld Procedure Development
Weld Process Consulting
MIG Process Training
Details
- Year established: 1998
Highlights and features
- 60 years of welding process expertise across 13 countries
- Proprietary training programs developed over 25 years
- Specialized in GMA, FCA, and TIP TIG process optimization
- Proven track record with Fortune 500 companies
- Focus on eliminating weld rework through process control
Services
Weld Process Training
Our training programs focus on GMA, FCA, and TIP TIG processes, teaching welders and engineers to optimize settings, reduce rework, and improve productivity. We emphasize practical, no-nonsense techniques over theoretical approaches, ensuring measurable results. Clients gain expertise in process ownership, cost analysis, and quality control.
Robot Weld Optimization
We analyze and refine robotic welding systems to eliminate inefficiencies, reduce downtime, and improve weld quality. Our methods include setting optimal parameters and training technicians to avoid trial-and-error adjustments. This ensures consistent output and significant cost savings for high-volume production.
TIP TIG Training
TIP TIG is a semi-automated process offering superior weld quality and productivity. Our training covers setup, best practices, and troubleshooting, enabling welders to achieve defect-free results with minimal spatter and distortion. This reduces rework and enhances mechanical properties for critical applications.
Weld Cost Analysis
We evaluate weld shop expenses, including labor, materials, and equipment, to identify inefficiencies. Our analysis provides actionable strategies to reduce costs by up to 60%, focusing on process control, consumable selection, and productivity improvements.
Flux Cored Process Consulting
We address common flux cored welding issues like porosity and slag inclusion. Our consulting services include parameter optimization, welder training, and process adjustments to ensure consistent quality and compliance with industry standards.
People
Ed Em Craig
Founder & Senior Weld Engineer
With 60 years in the welding industry, Ed Em Craig pioneered process control methodologies used by global leaders. He developed training programs adopted by ABB, Caterpillar, and NASA, and led teams at Commonwealth Fusion Systems to build the SPARC fusion reactor. His expertise spans GMA, FCA, and TIP TIG processes.
Questions
What welding processes do you specialize in?
We specialize in GMA (MIG), Gas Shielded Flux Cored (FCA), and TIP TIG processes, focusing on process control, cost optimization, and quality improvement.
How can your training programs benefit my company?
Our programs reduce weld rework, enhance productivity, and equip teams with actionable expertise in process ownership, saving millions annually in waste and downtime.
Do you offer on-site training or consulting?
Yes, we provide customized on-site training and consulting for global clients, tailored to their specific welding challenges and operational needs.
What industries do you serve?
We work with automotive, aerospace, shipbuilding, nuclear, defense, and manufacturing sectors, addressing complex weld quality and productivity issues.
How do you address robot welding inefficiencies?
We optimize robot GMA weld settings and train technicians to eliminate trial-and-error adjustments, improving quality and reducing downtime by up to 80%.
