Welding Equipment
Twenty years of CPSC NEISS emergency-room records for this consumer product category, combined with demographic breakdowns, multi-year injury trends, and matching recall notices.
Home Communication & Entertainment · CPSC Code 896
Down 16% over 5 years
The verdict
Welding Equipment carry a danger score of 36/100 (low risk), driven by roughly 13,312 ER-treated injuries a year that are declining by about 16% over the last five years.
- 36/100
- danger score (low risk)
- 13,312
- ER visits per year (avg)
- 2.0%
- end in hospital admission
- 15-24
- most-injured age group
Every figure is rendered from the CPSC NEISS record for product code 896 - last data year 2024.
PlainSafety danger score
How this 36/100 score is built
The score is computed from four CPSC-derived factors for welding equipment - no opinion, no editorializing:
- Injury volume13,312 ER visits/yr
- Severity (hospitalization rate)2.0%
- Fatality rate0.00%
- 5-year trend-16%
See the full methodology for the exact weighting of each factor.
What the CPSC Data Shows
Welding Equipment (CPSC product code 896, in the Home Communication & Entertainment category) generate an estimated 13,312 emergency-room visits every year in the United States, adding up to roughly 266,248 ER-treated injuries across the 20-year span from 2005 to 2024. PlainSafety derives a danger score of 36/100 for this category (low risk), combining raw injury volume, demographic reach, severity of outcome, and multi-year trend. The five-year trajectory shows that injury counts are declining by about 16% over the last five years, with the busiest year on record being 2007 (17,518 estimated ER visits) and the quietest 2020 (7,122 estimated visits).
The single most common ER diagnosis for welding equipment is radiation to the eyeball, accounting for approximately 135,388 visits across the 20-year NEISS window, followed by foreign body to the eyeball (40,630 cases). The 15-24 age group absorbs the largest share of injuries, about 73,326 cases over the NEISS window, and males appear slightly more often than the opposite sex in that cohort. Severity outcomes from the NEISS disposition field show that 2.0% of ER visits involving this product end in hospital admission or transfer.
Beyond the hospital-sampled NEISS projections, this page also aggregates 5 consumer incident reports filed directly on SaferProducts.gov, plus 20 anonymized ER narratives - together forming a layered picture of how welding equipment fail in real households. Every figure on this page comes from CPSC-published data: NEISS projects national estimates from a probability sample of about 100 U.S. hospital emergency departments, while SaferProducts.gov collects voluntary reports from consumers, manufacturers, and clinicians. The danger score, trend indicators, and demographic breakdowns update automatically when CPSC releases a new yearly NEISS file, which is why this page is dated 2024-12-31. For regulatory context, consult CPSC recall notices and the SaferProducts.gov public database linked below.
Annual Injury Estimates (2005–2024)
Source: CPSC NEISS national estimates CPSC NEISS national estimates Injuries represent ER-treated cases only
Who Gets Injured?
| Age Group | Male | Female | Total |
|---|---|---|---|
| 0-4 | 375 | 489 | |
| 5-14 | 2,467 | 238 | |
| 15-24 | 70,661 | 2,665 | |
| 25-34 | 65,814 | 1,010 | |
| 35-44 | 54,364 | 1,039 | |
| 45-54 | 37,708 | 414 | |
| 55-64 | 18,332 | 102 | |
| 65-74 | 7,814 | 104 | |
| 75+ | 2,516 | 0 |
Most Common Injuries
| Body Part | Diagnosis | Est. Injuries |
|---|---|---|
| Eyeball | Radiation | |
| Eyeball | Foreign Body | |
| Eyeball | Contusions, Abr. | |
| Eyeball | Other | |
| Eyeball | Derma/conjunct | |
| Hand | Burns, Thermal | |
| Finger | Burns, Thermal | |
| Lower Arm | Burns, Thermal | |
| Lower Leg | Burns, Thermal | |
| Face | Burns, Thermal | |
| Eyeball | Burns, Thermal | |
| Finger | Laceration | |
| All Parts Body | Electric Shock | |
| Finger | Puncture | |
| Foot | Burns, Thermal |
Severity Breakdown
ER Visit Narratives
Real anonymized emergency room reports from the CPSC NEISS database.
17 YOM WAS AT SCHOOL IN BUILDING TRADES CLASS USING A WELDER AND GOT SOMETHING IN EYE DX ABRASION EYE2 VFOREIGN BODY EYE
33 YOM USING MIG WELDER ENDED UP STABBING HAND WITH WIRE DX PUNCTURE WOUND HAND
29 YOM WAS WELDING YESTERDAY AND DID NOT USE THE APPROPRIATE HYPERADDUCTION. NOW HAD EYE PAIN AND IRRITATION. DX: WELDERS FLASH OF BOTH EYES
24YOM C/O EYE PROBLEM/WELDING ARC BURNS TO BOTH EYES. HE WAS WELDING WITHOUT USING A WELDING SHIELD. LEFT CORNEAL ABRASION. DX: PHOTOKERATITIS, BILATERAL
36YOM C/O SHOULDER/ARM PROBLEM. HAS RECURRENT ISSUES WITH SHOULDER WHICH HAVE WORSENED SINCE WELDING. RADIOGRAPHS NEGATIVE FOR ACUTE FRACTURE. COMPLAINS OF RIGHT LATERAL SHOULDER PAIN. DX: SHOULDER STRAIN
34YOM PRESENTS AFTER HE WAS STRUCK IN THE RIGHT THIGH WITH A SMALL STEEL ROD WHILE HE WAS DOING SOME WELDING DX: CELLULITIS AND ABSCESS OF UPPER LEG AND SKIN FOREIGN BODY
22 YOM BILAT EYE PAIN WELDING W/O PROTECTION DX; UVK
34 YOM WAS WELDING METAL WHEN A SPARK FLEW UNDER HIS PROTECTIVE GLASSES INTO HIS LEFT EYE. DX: FOREIGN BODY LEFT EYE.
59 YOM CHEST PAIN WHILE WELDING DX; CHEST PAIN
38YOM PRESENTS WITH REDNESS AND SWELLING AND PAIN TO HIS LEFT INDEX FINGER AFTER HE POKED IT WITH A WELDING WIRE DX: CELLULITIS
34YOM, C/O EYE TRAUMA RIGHT EYE, WELDING ACCIDENTALLY STABBED RIGHT EYE W/ PIECE OF METAL, BLURRY VISION & PHOTOPHOBIA DX: CORNEAL ABRASION RIGHT EYE
37 YOM PRESENTS WITH BILATERAL EYE PAIN. HE WAS WELDING HIS CAR WEARING A WELDING HOOD. IT WAS A DUSTY ENVIRONMENT. DX CORNEAL ABRASIONS
Consumer Incident Reports
Reports filed by consumers on SaferProducts.gov.
Welder was welding with a fibre-metal Model 110WH HLMT 110 WHITE SH 10 PC made by North Safety Products co., Cranston, RI, when the weld hood caught on fire around the lens and forehead area.
Welding goggles that I purchased failed, causing me to burn myself. I was using a new pair of welding goggles that I purchased just the day before to do some brazing of copper tubing in my basement. I had almost completed my braze, when I lifted up the shaded glass on the goggles (it's hinged) to inspect my braze, when suddenly the shaded glass fell from the goggles. I was holding the lit torch in my right hand, and I operated the goggles with my left hand. When the glass fell, I instinctively reached for it, causing the lit torch, with a large, multi-flame tip attachment, to come into direct contact with the back of my arm, causing a severe burn. I almost dropped the lit torch. I shut off the torch, removed the goggles, and then got a wet cloth on my burned arm. I inspected the goggles and noticed that they appear to have a manufacturing defect which caused this problem to happen. The frame that holds the shaded glass into the goggles is designed to allow the glass to be removed and replaced (possibly for different levels of shading?). The glass is retained by a piece of springy wire that is supposed to hook into holes on the left and right at the top of the frame. The hole on one side of that frame was defective. Instead of a hole through the plastic, the back-side was missing, so it was just a dent. As long as the shaded glass frame was down, it held the wire in place, but as soon as it was raised, the wire would spring out, thereby allowing the shaded glass to fall out. Here is a link to the product at Lowe's: http://www.lowes.com/pd_13867-47120-SGY-WELD14_0__?productId=50017000&Ntt=blue+hawk+welding&pl=1¤tURL=%3FNtt%3Dblue%2Bhawk%2Bwelding&facetInfo= Product name: "Blue Hawk Black Welding Safety Glasses" Item #: 13867 Product #: SGY-WELD14
My BernzOmatic propane torch started to leak propane through a small hole on the gas valve. The manufacturer claims that this is a safety in the event of an internal seal failure. I purchased this torch approximately 8 years ago and used it less than 10 times and it failed. The manufacturer seems to have no issue with their product failing after minimal use and feels that venting flammable gas in the direction of the operator is a good safety practice. After I discovered the failure I discontinued use and detached the propane cylinder. I have read on-line about others having the same issue. The torch is black plastic with a blue plastic grip and a red gas valve and ignition trigger. The blue handle says BernzOmatic and the number 307 is stamped near the ignition trigger. There are no other markings on the torch and no safety instructions or mention of the safety relief on the gas valve.
(12/8/2015The consumer is concerned that the machine can explode because it does not have safety valves. The consumer also stated that the product is poorly constructed. There is stainless steel welded to regular steel. Regular steel will rust and leak causing it to leak hydrogen and oxygen gas. The water and gas exchange chamber on the top of the machine is welded together by pieces of flimsy sheet metal that has a high possibility of rupturing if there is a flashback to the chamber. The water and gas exchange chamber does not have an emergency release valve in case of flashback. This will cause a major explosion. (12/08/2015) The consumer contacted the manufacturer with his concerns. He asked for his money and was refunded. He was advised to ship the product back to the company in California. The consumer still has the product. Here is a YouTube Video that will explain this King Kar 600 dangers I am talking about. https://wwwyoutube.com/watch?v=TGo3udd0t7g&feature=youtu.be Hello there I been dealing with HHO Gas machines for a long time. I understand fully the dangers of the manufacturing of the machine to be safe or not. I ordered this King Kar 600 machine from China and I was promised it would be high-quality and safe to use. After a thorough examination I found this machine to be unsafe for the public and for commercial applications. There is many different issues going on with this King Kar 600 model that you will see clearly in our video on YouTube. I thought doing a YouTube video would be great because videos give you a 360 degree outlook on what is taking place instead of pictures that do not say anything showing compared to a video that is show and tell. This video is on YouTube marked unlisted and not available to the public to be viewed. Only people that are given this link has the permission to view this video. Here is a YouTube Video that will explain this King Kar 600 dangers I am talking about. https://www.youtube.com/watch?v=TGo3u
I was welding with a brand new auto darkening helmet and it failed to darken enough to protect my eyes . As a result I recieved burns to my retina on both eyes . Worse was my left eye .
Product Recalls
Search for active and past recalls related to welding equipment on the CPSC website.
Frequently Asked Questions
How dangerous are welding equipment?
Based on 20 years of CPSC data, welding equipment have a danger score of 36/100 (low risk). An estimated 13,312 ER-treated injuries occur annually in the U.S. related to this product category.
What are the most common injuries from welding equipment?
The most common injury is radiation to the eyeball, accounting for approximately 135,388 injuries over 20 years.
Are injuries from welding equipment increasing or decreasing?
Down 16% over 5 years.
Who is most at risk for welding equipment injuries?
The 15-24 age group accounts for the most injuries, with approximately 73,326 cases recorded over 20 years. Males are more frequently injured in this age group.
What happens when someone is injured by welding equipment?
Of all ER visits involving welding equipment, approximately 2.0% result in hospital admission. The majority of patients (98.0%) are treated and released from the emergency department.
How can I report a safety problem with welding equipment?
You can file a consumer incident report at SaferProducts.gov, the official CPSC reporting portal. Reports help the CPSC identify emerging hazards and trigger investigations or recalls. You can also call the CPSC hotline at 1-800-638-2772.
Related Products in Home Communication & Entertainment
Safety Guides
What this means for you
Treat the 36/100 score as relative risk between products, not your personal odds of injury.
- See where this category ranks against every other tracked product. Full rankings
- Injuries cluster in the 15-24 age group, take extra care if that describes your household.
- Check for active recalls on this product before you assume it is safe. CPSC recalls
NEISS estimates ER-treated injuries from a national probability sample of hospitals; they do not capture injuries treated elsewhere or not treated at all.
Data: CPSC National Electronic Injury Surveillance System (NEISS) 2005–2024 and SaferProducts.gov consumer incident reports. Injury estimates are based on a nationally representative probability sample of U.S. hospital emergency departments. This page is for informational purposes only and is not affiliated with the CPSC.
Read our methodology - how this data is sourced, scored, and verified.