Built from humble roots, Weldall Manufacturing is tackling the metalworking industry’s toughest challenges
Epitomizing manufacturing excellence, Weldall Manufacturing (Weldall) is a big-name company with humble roots. Founded in 1973, just over 50 years ago, the company is dedicated to providing large-scale metalworking and fabricating solutions to customers across the United States.
Upholding the highest standards of quality and integrity, Weldall is a full-service contract manufacturer that’s trusted by leading businesses across a wide range of industries, primarily serving the automation, construction, mining, nuclear, rail, energy and power generation, material handling, and government markets.
Priding itself on solving the industry’s most difficult dilemmas, Weldall is a business with an intellectual core and a beating heart. To learn more about the company’s journey to success, Manufacturing Today sits down with the man that made it all happen: Founder, President and CEO, Dave Bahl Sr.
“I founded Weldall Manufacturing in 1973 after borrowing $800 and lease-purchasing a welding machine,” Dave begins. “Back then, we operated out of a 500 square-foot space in West Allis, Wisconsin, but my focus was delivering reliable craftsmanship and building trust with every project. Those principles have stayed at the heart of our business as we’ve grown.
“Over the years, with the dedication of our incredible team, we’ve been able to expand far beyond what I initially imagined. Today, Weldall operates out of three locations with over 225,000 square feet of manufacturing space and over 275 employees. We’ve become a leader of large, complex weldments with the capability of lifting 400,000 lbs, serving a variety of industries, and I’m proud of how we’ve maintained our commitment to excellence and long-lasting customer relationships through it all.”
With a large variety of capabilities, Weldall provides the full package. From welding to machining, fabricating to finishing, the business offers a diverse scope of comprehensive turnkey services and solutions, and works with all grades of carbon steel, stainless and aluminum.
“We take projects from initial concepts to full production, offering solutions for prototypes and large-scale production alike,” Dave elaborates. “Our team excels at tackling intricate weldments and delivering precision-engineered components that meet even the most demanding specifications.”
Driven by technology and innovation, Weldall is constantly investing in new technologies and equipment to stay ahead of the curve in the ever-evolving industry and continue providing the best solutions for its clients.
“Keeping up with advancements is crucial to staying ahead in this industry,” Dave highlights. “Recently, we acquired a state-of-the-art robotic welding system, a 700-ton CNC press brake with a 20-foot-long auto-adjustable bottom die, and other precision machining equipment, enabling us to deliver even more complex and innovative solutions. In fact, over the last six years, Weldall has reinvested on average three million dollars per year in new equipment. These upgrades not only enhance our capabilities but also help us work more efficiently, meeting our customers’ needs with greater accuracy and speed.
“Additionally, we’ve begun integrating artificial intelligence (AI) and machine learning (ML) into our processes to optimize production workflows, improve predictive maintenance and increase overall efficiency. These technologies help us anticipate potential issues before they arise, reduce downtime, and ensure a higher degree of precision in our operations.”
To ensure that it is able to remain at the forefront of industry advancements, Weldall’s close partnership with the American Welding Society (AWS) is illustrative of the business’ passion and dedication to the sector.
“Our relationship with the American Welding Society has been invaluable in ensuring our team operates at the highest level and helps us to stay ahead in an ever-evolving industry,” Dave shares. “At Weldall, we have a Certified Welding Educator on staff and five AWS Certified Welding Inspectors, who are certified to ASNT TC 1a PT Level II and MT Level II. In fact, all of our welders are certified to AWS D1.1., and most of them are also certified to ASME (American Society of Mechanical Engineers), NAVC (Naval Sea Systems Command), CWB (Canadian Welding Bureau) & EN (European Welding Standard).”
Indeed, when we asked Dave about the factors he feels have contributed to the longevity and ongoing success of the business, he emphasized the value of building and nurturing robust relationships with his customers, his team and his suppliers.
Strong relationships
“In addition to our relationship with the American Welding Society, we’ve built strong partnerships with suppliers, industry associations, and local schools. One partnership I’m especially proud of is our collaboration with GPS Ed,” Dave reveals. “In 2023, we worked with them to build a classroom at our headquarters, and, in the summer of 2024, we opened the Weldall Education Center. This program brought in over 30 students, and we’re thrilled to say that 12 of them are now interning with us in welding, fabrication, and maintenance roles. These students are the future of our industry and investing in their development is key to sustaining Weldall’s growth.
“Our success boils down to staying true to our principles, which include delivering dependable results, building trust and valuing the people behind the work. Our
team has always been at the heart of what we do – they’re skilled, dedicated, and committed to helping our customers succeed.
“Over the years, we’ve also built strong relationships with our customers, ensuring they know they can rely on us time and time again. Our growth has always been driven by our dedication to delivering exceptional results and doing the right thing for our customers. Building long-term trust and partnerships with clients has been critical, as has our investment in our people. The passion and expertise of our team are the foundation of everything we’ve accomplished, and their commitment to meeting customer expectations has allowed us to grow steadily over the years.”
Learning culture
Aside from contributing to its tremendous growth, Weldall’s strong partnerships and unbreakable values have helped to support the business amidst the current challenges faced by the wider industry.
“Labor shortages and supply chain disruptions are among the biggest challenges in manufacturing today,” Dave explains. “At Weldall, we’ve tackled these issues by fostering a culture that values continuous learning and career development, ensuring we attract and retain top talent. On the supply chain front, our strong relationships with vendors and proactive planning allow us to mitigate disruptions and stay consistent in delivering for our customers.”
As 2024 draws to a close, Weldall Manufacturing is looking forward to a bright future brimming with exciting new projects and further growth and development. The business is keen to continue building on its legacy, seizing new opportunities and further empowering its customers and employees.
“Five years from now, I envision Weldall as an even stronger partner for our customers, with expanded capabilities and a larger footprint in the industry. I want us to continue being a leader in innovation while investing in the next generation of skilled workers. Our commitment to excellence and fostering strong relationships will remain at the core of our success,” Dave proposes.
As our interview draws to a close, Dave reflects on the immense journey both he and Weldall have experienced thus far. We asked him what advice he’d give to someone wanting to start their own business, and Dave offers some valuable advice.
“I’d tell them to focus on delivering work they can be proud of and to always treat their customers and employees with respect. Building trust takes time, but it’s the most important investment you can make. Surround yourself with good people and be ready to adapt to challenges – they’re inevitable, but they’re also opportunities to grow.”