Injury to the ear in welders is a recognized but poorly documented entity. The risk for ear injury from molten metal or hot sparks produced during welding procedures is low, but the effects can be significant. Burns, tympanic membrane perforations and chonic otorrhoea are the most common results. One case recently experienced at our institution highlight the risk that exists for middle ear injury. The traumatic thermal injury was caused by a metal spark perforating the tympanic membrane during welding. Neither subject was using ear protection at the time. The use of ear protection is strongly advocated during welding operations that place the ear at risk.