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In 1998, Welling was discovered by a catalogue camera scout at a party in Nantucket who suggested he try modeling. In 2000, Welling relocated to Los Angeles where he modeled for Tommy Hilfiger, Abercrombie & Fitch, and other print ad campaigns, while pursuing an acting career. He appeared in some commercials and a music video. Welling's first major acting role was as karate teacher Rob Meltzer, a younger love interest of Amy Brenneman on the CBS series Judging Amy that aired in 2001. Welling also had a small role in UPN's Special Unit 2 and also appeared in the debut episode of the FOX sitcom Undeclared. He was cast in series Smallville after a nationwide search for the actor to play Clark Kent.

In December 2003, Welling played Charlie Baker, the oldest son in a family of 12 children in the film Cheaper by the Dozen, a remake of the 1950 original. In 2005 Welling appeared in two other films as well. He played Nick Castle in The Fog which was a remake of John Carpenter's 1980 film. He also reprised his role as Charlie Baker in Cheaper by the Dozen 2. (wikipedia.org)