US Navy shipbuilder tests smart welding that scans workpieces and auto-adjusts live

The US shipbuilding industry has spent years looking for ways to increase production while addressing skilled labor shortages and growing demand from the Navy. Shipyards have steadily introduced robotics, digital manufacturing tools, and automated fabrication systems to improve efficiency, but many welding operations still depend heavily on manual work. Against that backdrop, HII has begun testing intelligent welding technology developed with South Korea’s HD Hyundai Heavy Industries (HHI), marking another step in a broader effort to modernize naval ship construction. Smarter welding operations The pilot program will bring intelligent mechanized welding systems to HII’s Ingalls Shipbuilding yard in Mississippi. The initiative follows a strategic partnership the two companies signed in 2025 to explore closer cooperation in naval shipbuilding and industrial technologies. Unlike conventional mechanized systems, the new equipment identifies workpieces automatically and adjusts welding positions in real time. It also records production data that engineers can use to improve quality control, process optimization, and manufacturing traceability. Ingalls plans to deploy the equipment in unit fabrication areas where workers currently perform most welding manually. Before introducing the systems, the shipbuilder verified that the equipment meets existing US Navy fabrication standards. Brian Blanchette, president of Ingalls Shipbuilding, said the yard already operates some of the most advanced automated production systems in the US shipbuilding industry. “Our investments already cover automated panel lines, robotic bulkhead fabrication and numerous digital manufacturing tools,” Blanchette said. He added that the new pilot expands automation into additional production areas while allowing Ingalls to share manufacturing expertise with HHI. Technology exchange expands The welding project emerged after engineers from both companies spent three days evaluating production methods and automation technologies at Ingalls Shipbuilding. During the technical exchange, Ingalls demonstrated its hybrid laser welding capabilities, robotic manufacturing systems, and production layouts designed to streamline ship construction. Those discussions helped identify practical opportunities where HHI’s intelligent welding technology could fit into existing US shipyard operations. Dr. Won-ho Joo, chief executive of HHI’s Naval & Special Ship Business Unit, described the pilot as another sign of growing technical cooperation between the companies. He said both shipbuilders expect the collaboration to improve production efficiency while creating greater value for future customers. Broader automation push The welding systems represent only one piece of HII’s wider manufacturing strategy. Ingalls Shipbuilding and Newport News Shipbuilding are evaluating additional robotic fabrication cells, collaborative robots, additive manufacturing, automated steel processing equipment, and integrated production software that provides real-time visibility into ship construction. HII has also launched its High-Yield Production Robotics (HYPR) initiative, which partners with physical AI companies to develop intelligent robotic tools for shipyard workers. The effort focuses on augmenting the existing workforce instead of replacing skilled trades. As the US Navy seeks to expand and maintain its fleet, shipbuilders face increasing pressure to deliver vessels faster without compromising quality. HII believes greater use of automation, combined with partnerships that bring proven manufacturing technologies into American shipyards, could help meet that challenge while making demanding jobs such as welding safer and more efficient.Recommended ArticlesGet the latest in engineering, tech, space & science - delivered daily to your inbox.Aamir is a seasoned tech journalist with experience at Exhibit Magazine, Republic World, and PR Newswire. With a deep love for all things tech and science, he has spent years decoding the latest innovations and exploring how they shape industries, lifestyles, and the future of humanity.