In this study, the structural analysis and welding performance experiments were performed to reduce the weight of the semi-automatic TIG welding device. The structural analysis based on finite element method was performed on the lightweight design of the wire feeder's main frame to evaluate the structural safety and straightness of the lightweight frame. To reduce the weight of the welding wire feeder, the step motor was changed to a servo motor and a pinion gear made of lightweight reinforced plastic material was applied. In addition, a new type of welding torch was developed to reduce the weight of the welding torch and to supply more effective fillers. As a result of performing the TIG welding experiment using a prototype of TIG welding device consisting of a lightweight frame, feeding device and welding torch, it was confirmed that the working criteria were satisfied in terms of welding speed, welding bead shape, feeding uniformity and torch durability. The developed lightweight TIG welding device is expected to improve welding productivity and work convenience.