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The US manufacturing industry is currently facing a welding workforce shortage which is largely due to inadequacy of widespread welding training. To address this challenge, we present a Virtual Reality (VR)-based training system aimed at transforming state-of-the-art-welding simulations and in-person instruction into a widely accessible and engaging platform. We applied backward design principles to design a low-cost welding simulator in the form of modularized units through active consulting with welding training experts. Using a minimum viable prototype, we conducted a user study with 24 novices to test the system’s usability. Our findings show (1) greater effectiveness of the system in transferring skills to real-world environments as compared to accessible video-based alternatives and, (2) the visuo-haptic guidance during virtual welding enhances performance and provides a realistic learning experience to users. Using the solution, we expect inexperienced users to achieve competencies faster and be better prepared to enter actual work environments. 

Augmented reality (AR) is an efficient form of delivering spatial information and has great potential for training workers. However, AR is still not widely used for such scenarios due to the technical skills and expertise required to create interactive AR content. We developed ProcessAR, an AR-based system to develop 2D/3D content that captures subject matter expert’s (SMEs) environment-object interactions in situ. The design space for ProcessAR was identified from formative interviews with AR programming experts and SMEs, alongside a comparative design study with SMEs and novice users. To enable smooth workflows, ProcessAR locates and identifies different tools/objects through computer vision within the workspace when the author looks at them. We explored additional features such as embedding 2D videos with detected objects and user-adaptive triggers. A final user evaluation comparing ProcessAR and a baseline AR authoring environment showed that, according to our qualitative questionnaire, users preferred ProcessAR.