Current research and development processes of novel welding consumables constitutes a great cost and requires a lot of time and resources. LNU WML has requested a novel small batch GTAW welding consumables manufacturing process that is cost-, time-, and resource-efficient. The study was conducted in accordance to DFSS, a product developing process under the overarching scientific engineering method “Systems Engineering”. The DFSS process consists of four stages, where stage one and two were completed.  This has resulted in the development of three novel concepts, and key parameters has been established. One novel concept has been selected by the client and an experiment has been conducted that proves the principle functionality of the novel concept.  Recommendations on how to proceed to a finished, usable product is expressed as a recommendation of a continuation of the DFSS-process, a conduction of a secondary experiment and suggestions for key parameters.