The material most commonly used for weld fasteners is low-carbon steel such as 1010. Welded parts must be portable enough to be carried to the welder. Use of portable welding equipment with these types of fasteners is not recommended.

Production volume should be large enough to justify tooling costs. At least 1,000 parts are usually necessary to make the application of weld fasteners economically feasible.

Greatest use of weld fasteners is with sheet-metal parts from 0.030 to 0.125 in. thick. However, almost any fastener can be welded to any thickness of material as long as the materials are compatible, the welding operation is controlled, and the fastener itself is properly designed and not heat treated.