MIG vs TIG Welding: Applications for Laser Cuts + Pros & Cons

When it comes to assembling custom laser cut parts, welding remains one of the most reliable and permanent joining methods available. Among the many welding processes, two stand out as the most common: MIG welding (metal inert gas) and TIG welding (tungsten inert gas).

While both use shielding gas and an electric arc to fuse metal, their differences in precision, speed, cost, and material compatibility can heavily influence which one is best for your project. If you’re deciding between MIG vs TIG welding, understanding the nuances of each process is critical to achieving strong, reliable welds that complement your laser cut designs.

MIG and TIG Welding: 7 Key Differences

Although MIG and TIG welding both rely on electricity and shielding gases, their setups and applications diverge significantly. Below are the main distinctions to guide your choice.

1. Power source

• MIG Welding: Uses a DC (direct current) power source, which provides arc stability, minimizes spatter, and works well on thinner metals.
• TIG Welding: Offers both DC and AC (alternating current) options. This flexibility allows TIG welders to work with a wider range of metals, including aluminum, making it the preferred choice for complex materials.

2. Metal selection

• MIG Welding: Best for mild steel, carbon steel, and cast iron—materials often chosen for strength-focused applications. MIG welding is forgiving but produces welds that may require grinding for a clean finish.
• TIG Welding: The go-to for stainless steel, aluminum, and non-ferrous metals. TIG welding’s precision makes it ideal when cosmetic appearance and warping control are critical.

3. Electrode

• MIG Welding: Employs a consumable electrode (wire) fed through the torch. The electrode itself melts into the joint, adding filler material continuously.
• TIG Welding: Relies on a non-consumable tungsten electrode to generate the arc. A separate filler rod is added manually when reinforcement is needed.

4. Shield gas

• MIG Welding: Commonly uses a mix of argon and carbon dioxide. Effective for thick materials but prone to disruption outdoors. Flux-core MIG offers a gasless option.
• TIG Welding: Typically uses pure argon or argon mixed with helium/nitrogen. These gases protect the weld from contamination and keep the tungsten electrode cool.

5. Welding quality

• MIG Welding: Produces strong, durable welds suitable for heavy-duty applications, but appearance can be rougher.
• TIG Welding: Delivers precise, aesthetic welds with fine bead control—ideal for visible joints or intricate designs.

6. Speed

• MIG Welding: Faster, thanks to its semi-automatic wire feed. It’s widely used in high-volume production.
• TIG Welding: Slower because filler is applied manually. This makes TIG better for detail work but less efficient for mass production.

7. Cost

• MIG Welding: Machines are generally more affordable, and the process is quicker—making it the budget-friendly option.
• TIG Welding: Equipment costs more, and slower production increases labor expenses. Precision comes at a price.

How Welding Techniques Can Complement Laser Cutting 

Pairing laser cutting with welding is a natural fit. Laser cut parts arrive dimensionally accurate and clean-edged, making them ideal candidates for strong, consistent welds.

• Durability: Welds provide a permanent solution that withstands stress better than mechanical fasteners in many cases.
• Strength: Welded joints often match or exceed the strength of the base material.
• Design Flexibility: Most metals suitable for laser cutting can also be welded, opening endless design opportunities.

Step-by-Step: Preparing Your Laser Cut Parts for MIG or TIG Welding

Although TIG welding and MIG welding vary by the equipment used and the application requirement, the initial steps to begin welding are similar. 

Step 1: Purchase a welder

MIG welders tend to be more affordable, with some cheaper options sitting at $140 and going up to $1000. TIG welders are the more expensive option, starting around $200 and reaching $2500 for standard models. Which one you purchase depends on what you need your welds to accomplish, although MIG welding is the more beginner friendly option. (Depending on the method you choose, you will also need to purchase shield gas and filler rod.) 

Step 2: Prep your work area

Ideally, you are welding inside and in a well-ventilated area. Your workspace should be cleaned to prevent debris from getting into the weld, and you should have a metal surface nearby to set a grounding clamp.

Step 3: Clean your metal

The surface needs to be clear of debris, scaling, oil, or any grime build up. For some steels, this means lightly grinding the surface and cleaning with acetone. For metals like aluminum, this means just wiping it off with isopropyl alcohol.

Step 4: Begin welding

There are several techniques to try depending on your welding method and final application, but initially you will need to tack the base metals before actually welding them. In this process, clamp the two parts together and alternate weld beads to prevent warping. Once the tacking is complete, you’re ready to weld the parts completely.

Step 5: Grind out the welds

You won’t always need or want to grind your welds down, but with MIG welding especially, it can help create a smoother and more aesthetic surface. An angle grinder can achieve this surface easily.

The techniques you need to learn to create successful welds will take practice, and we highly recommend working with an experienced welder for your initial attempts. Starting with a material like laser cut stainless steel would be best because it’s one of the more simple metals to weld, and it’s an affordable, clean option that doesn’t take much prep. Most importantly, don’t get discouraged. The best welding takes years of practice and even the most experienced welders are still learning new techniques and tricks!

MIG vs TIG Welding: Pros and Cons

MIG and TIG welding, although unique, both have a place in joining laser cut metal parts. MIG welding is more beginner friendly and TIG welding is more precise and clean, and MIG welding is also better suited for strength applications while TIG welding is suited for more versatile projects. But the best way to decide between MIG welding and TIG welding is identifying the materials you intend to use in your project. 

Some of the best laser cut metals for welding are:

• 304 and 316 stainless steel
• Mild steel
• Aluminum
• Copper
• AR500

Our materials guide can help you navigate the best laser cut metals for welding and find their ideal applications. 

Let’s summarize the advantages and disadvantages of both MIG and TIG welding:

Advantages of MIG Welding

• Fast welding process: MIG welding takes the least amount of time between set up, preparation, and actual welding. Clean, strong results are achievable with little time sunk in.
• Cost-effective: As mentioned above, MIG welding is the most affordable method by far. There are fewer consumables required and the unit itself is cheaper than other options.
• Accuracy: Since the welder only has to manipulate the torch, MIG welding is highly accurate with little effort needed.
• Semi-automatic: With a filler rod/electrode that is mechanically fed through the torch, MIG welding is the only semi-automatic welding process.
• Delivers a clean weld: With a little practice, MIG welding creates a clean bead with little spatter. 
• Versatility: MIG welding lends itself to a wide variety of metals and can be used for a number of unique applications.

Disadvantages of MIG Welding

• Less stable and less reliable due to arc stability problems: Because MIG welding can only use a DC power source, the arc through the electrode is less stable and can cause mistakes in the weld.
• Not environmentally friendly: MIG welding produces a high amount of ozone and nitrogen oxides during the welding process.
• May cause rust formation: If not properly cleaned, the parent metals can rust after MIG welding since the oxide layer cannot seal the weld fully.
• Can burn thin materials because of less operational control: It is easy to burn through metals with MIG welding if you can’t move the torch fast enough. This is why MIG is better suited for thicker materials.
• It requires the process to be run indoors because of the shielding gasses: Because MIG welding shield gasses are lighter than oxygen, they can get carried away leaving the welds and parent metal unprotected. MIG welding must be done inside.

Advantages of TIG Welding

• Precision and accuracy: TIG welding is even more accurate than MIG welding thanks to its manual control.
• It is aesthetic: TIG welds have a tendency to be cleaner, more uniform, and just overall more aesthetically pleasing than MIG welds.
• It is more eco-friendly: The gasses produced and used in the TIG welding process, such as argon, are more environmentally friendly.
• Better operational control: Although it takes some finesse, the separate filler rod and torch allow for greater manual control by the welder.
• It reduces maintenance and operating costs by using non-consumable electrodes: MIG welders have to constantly purchase and replace the electrodes in their torches, while TIG welders just have to use separate filler rods.

Disadvantages of TIG Welding

• It is more expensive: TIG welding units are more expensive overall and the process takes more time. So whether you’re doing it yourself or outsourcing it, TIG welding is the more expensive option.
• Requires a clean surface: All parent metals to be TIG welded have to be thoroughly cleaned and sometimes lightly ground to give the welds a clean surface to adhere to.
• Requires an experienced operator: TIG welding is not beginner friendly and takes some practice to accurately weld holding both the filler rod and the torch.
• Time-consuming welding process: MIG welding allows you to breeze through the welding process but the precision required of TIG welding takes time. 

Applications of MIG and TIG Welding with Laser Cuts

MIG welding and TIG welding are best suited for entirely different applications. Each has the same value in different arenas, and choosing the best option for your project depends on several key factors.

MIG Welding Applications:

• Structural frames and brackets
• Automotive repair with thicker steel
• Long production runs where speed matters
• Projects where aesthetics are secondary to strength

TIG Welding Applications:

• Custom aluminum enclosures or housings
• Fine artistic or decorative work
• Thin-walled tubing or sheet assemblies
• Short runs requiring precision

Choosing the Right Method for Your Project

Choosing the right welding method for your project is ultimately up to you. There are advantages and disadvantages to both options presented here, and what you decide to do is dependent upon the metal you’re working with, the final application of the project, and what your goal as the welder is. Is it strength and speed? Or precision and aesthetics? If you need some more help deciding, check out this article on our best welding tips from SendCutSend’s welding experts.

If you’ve read through this article and decided welding just isn’t for you, you can find other methods for joining laser cut parts on our blog. Be sure to look through our full catalog of high quality materials and services to find the best fit for your next project!

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MIG vs TIG Welding FAQs