An applicator mitt assembly system comprises an applicator mitt tooling including: a tooling body having a mitt-perimeter cutter and weld bead thereon which are shaped to a perimeter of a mitt to be cut; a heating element associated with the tooling body which is shaped so as to substantially match a shape of the weld bead to create a perimeter weld for the mitt when engaged with the tooling body; and an ejector platen which is actuatable relative to the tooling body to eject a cut and welded mitt. A conveyor device is adapted to feed mitt material towards the tooling and a tooling actuator adapted to actuate the tooling relative to the conveyor device to allow the cutter to cut mitt material at the conveyor device. A discrete applicator mitt tooling, method of assembling an applicator mitt, and welded applicator mitt are also provided.