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Chosing The Right Welding Fume Extractor

 

Welding fumes are more than just a bit of smoke - they contain fine metal particles, gases and chemical vapours that can seriously impact your health over time. Australian Legislation, enacted in all States of Australia since 2024, is also very tough on Fume Control. So if you’re welding regularly, you need a plan to manage fumes properly. 

In this article we compare the common methods of controlling and protecting personnel from welding fumes.

 

Compare Fume Extractors By Application

In the following table we compare the common extraction methods vs their suitability in different applications. 

Type	PAPR Helmet	Mobile Extractor (LEV)	On-Torch Extraction	Portable Extractor	Downdraft Table	Ducted Extraction
Fumes extracted at / close to the source	❌	✔️	✔️	✔️	✔️	✔️
Reduces fumes for all workers in the environment	❌	✔️	✔️	✔️	✔️	✔️
Suitable Processes:
MIG, Downhand / Horizontal Position	✔️	✔️	✔️	✔️	✔️	✔️
MIG, Vertical & Overhead Position	✔️	✔️	❌	✔️	⚫	✔️
TIG	✔️	✔️	⚫	✔️	✔️	✔️
Stick / MMA	✔️	✔️	❌	✔️	✔️	✔️
Plasma & Oxy Cutting, Grinding, Gouging	✔️	⚫	❌	⚫	⚫	⚫
High fume volume Eg: some flux-core wires, frequent use, welding over long periods, etc	✔️	⚫	⚫	❌	⚫	⚫

✔️ Suitable/applicable   ❌ Not suitable/applicable   ⚫ Depends on unit/model capability & specific application

 

 

Comparing Fume Extractor Types: Advantages and Limitations

Here we cover some of the key pros and cons of the main types of welding fume extraction systems.

Fume Control System	Pros ✔️	Cons ❌
Welding Helmet with PAPR Respirator	Relatively low cost for initial purchase Very mobile and allows for unrestricted movement Quickly & easily deployed Powered air provides additional operator comfort	Only protects the user Does not remove fumes from the environment, or protect others in the environment Depends on battery power Requires frequent filter replacement/cost Operator carries additional weight & bulk
Mobile Fume Extractor (LEV)	Extracts fumes at the source Can be moved to different locations Versatile: can be easily deployed, and utilised only where/when needed by each operator Easy to maintain Does not interfere with operator ergonomics or comfort Depending on model/brand, are suitable for wide range of applications including: MIG, Stick, TIG, Grinding, Plasma, Oxy, Gouging	Need to be manually moved to the fume source / welding location In very confined spaces, wall mounted, or other systems may be better option May not be ideal where the welder is having to move very frequently over a wide area
Fume Extraction MIG or TIG Welding Torch	Extracts fumes directly at the point of generation for high efficiency removal Eliminates need for additional set up / movement, with extraction point always at the fume source	NOT suitable for Grinding, Stick/MMA welding, Plasma cutting, or Gouging Typically NOT suitable for vertical or overhead welding, or where there is confined space at the weld joint  Torch is bulkier, heavier, and more cumbersome than standard torches (some are better than others) Ongoing cost of torch consumables can be significantly higher than standard torches
Portable Extractor	Captures fumes directly at the arc or torch High mobility, compact, lightweight Ideal for maintenance, on-site repairs, or fieldwork Suitable for MIG, TIG, stick, even light cutting, depending on make/model	Less suction power & capacity vs other systems, not suitable for high-fume processes or long-duration welding  Extraction nozzle or hood must be manually positioned close to the arc  Small filter: fills up quickly, frequent cleaning or replacement required
Downdraft Table	Extracts fumes at the source Depending on model/brand, suitable for wide range of applications including: MIG, Stick, TIG, Grinding, Plasma, Oxy, Gouging Hands-free operation, does not interfere with operator ergonomics Ideal for training and production Doubles as a sturdy workbench, saving space and improving workflow	Not suitable for large components / structures that can't be placed on the table Larger tables typically require 3-phase power supply May not work well for workpieces that block the airflow path or are too distant from the table surface
Ducted / Central Fume Extraction System	Extracts fumes at the source Suited to large-scale workshops, especially if all workstations are typically active at the same time Minimal maintenance, or down time for operators	High installation cost Time consuming to procure and install Can be inefficient if workstations are used at different times, and/or some workstations are not always utilised Not suitable where portability & flexibility is required