From an 800 sq ft pole barn to a 4,000 sq ft shop, Devin shares how Lichen leveled up: team, layout, and automation. We cover the R450 cobot project, M300 wins, live‑tool lathe realities, and building a stable, sustainable operation without the chaos.

Check out Devin’s IG @lichen_mfg

and check out his podcast Incremental at https://open.spotify.com/show/5pjzm7sFZrumDHv2eqytg5

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Curt of Confounded Machine shares how a garage hobby became a thriving EDC pen brand. We dive into retrofitting a Hardinge, moving to a Syil X5 , iso-grid grips, entropic anodizing, and his new “Mech One” mechanism.

Rigibore RADS video mentioned: https://www.youtube.com/watch?v=o0pM5cKUKSA

Check out Curt’s IG @confoundedmachine

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Jamie Peacock of JSpec Engineering and The Lone Machinists podcast joins to talk one‑man‑shop reality, from building and retrofitting machines to launching the Anchor Point zero‑point system. We hit in‑house anodizing, adding a 4th on Siemens, and why relationships beat everything in business.

Link to the article discussed in the episode: https://www.linkedin.com/pulse/lets-talk-cheap-labour-expensive-mistakes-danica-peacock-cqrsf/ Check out Jamie's IG @jspec_engineering

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California updates with Zap, CMM finally dialed in, HyperMill setup progress, pin finisher optimization, RO water planning, and some honest programming errors. Topics include surface roughness tools, machine comparisons, cost tracking, floating tap holders, and technology perspectives.

Check out Zap's IG @zap.consulting

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Juan March returns with InFab co‑founder Blake Nazario to share how a shop-floor problem became a purpose-built ERP for high-mix job shops. We cover InFab’s beginnings, its rebuild for multi‑tenant use, ITAR/GovCloud and CMMC, plus AS9100 tools. Juan also updates us on Jax’s growth: a larger facility, a Datron ML Cube, DMG DMC 85 with integrated pallet pool, a new CMM, and an industrial “Roomba.” We wrap with quoting realities, roadmap, and practical lessons on communication and traceability.

Check out Juan’s IG @jaxmfg

InFab's IG @infab.app

and learn more about InFab at infab.app

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Zap, Justin Gray, and I trade wins, war stories, and hard lessons. Justin breaks down Toolpath’s CAM automation progress—constraints, search space control, and getting from “seven ops” to the three you actually want—plus new work on undercuts and 3+2. Zap brings DMG mill‑turn tales, a 1.5× tool life bump, and the hidden cost of tool library drift. I talk CMM headaches and adding a newer manual machine. Then rapid‑fire Q&A: VF‑2 vs. higher‑end 30×16 choices, our aluminum rougher, Blum Z‑nano supremacy, zero-point with no probe, wear comp best practices, zero‑point/G10 for legacy setups, and real ways to recruit students (FIRST and desktop CNC done right). Stick around for a Mastercam RAM allocation fix, a Fusion post warning, Freddy bee‑duty, and why one‑piece flow still wins.

Check out Justin’s IG @justinsgray and Toolpath Labs @toolpathlabs or https://www.toolpath.com/

Check out Zap’s IG @zap.consulting

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From the coolest $10 aviator safeties to a future “van-cast,” Dylan and Zap catch up on shop projects and a mountain of listener Q&A. Dylan shares a smart coolant-dosing build, a bio-renewing parts washer win, PH Horn saw success, and ballbar/linear guide fixes that tightened up the Speedios. Zap details big wins on a project, Mastercam Mill-Turn on a Nakamura, and rolling out prepaid-hours plus Asana API automation. We dig into roughing tool holders (powRgrip, hydraulic, shrink), mist collectors, workholding vs toolholding, and more!

Check out Zap's IG @zap.consulting

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Patrick McClintock (@job_shopper_tn) joins me this week to discuss his unique journey from tech school to becoming a skilled machinist and programmer. We explore his decade at Galyon Manufacturing, his transition to RbSA Industrial working on tube bending tooling, and the challenges of changing jobs after building deep connections. Patrick shares the story behind growing his Instagram, the creation of the Impractical Machinists podcast, and gives us his best Yayhoo impression. We also talk about his experiences with probing in Fusion, finding the right balance between caring about your work and your well-being, and the value of quality workholding solutions.

Check out Patrick's IG @job_shopper_tn

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Help support the podcast at https://www.patreon.com/Withintolerancepodcast

Zap joins me in the studio for our first-ever video recording! We share updates from both our shops, with Zap detailing his extensive travels and successful business model revamp. I discuss recent shop improvements, material supplier frustrations, and a surprising visit from wastewater management. We answer listener questions about optimal shop layouts, machine installation planning, and whether premium machines are worth the investment.

Check out Zap's IG @zap.consulting

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Denis Basaric of KafaTek shares his fascinating transition from software engineer to manufacturer of premium espresso grinders. We discuss his pursuit of perfection - from designing coffee burrs with 5-micron adjustability to implementing robotic automation and sophisticated QC processes. Denis also explains the technical differences between burr designs, his philosophy of building products meant to last generations, and the challenges of maintaining aerospace-level precision in a small shop environment. 

Check out Denis's IG @kafatek

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Help support the podcast at https://www.patreon.com/Withintolerancepodcast

#instamachinist #withintolerancepodcast #kafatek

From Finance to Fixture plates - John Saunders reveals the winding path that led to creating NYC CNC and Saunders Machine Works. We discuss his transition from investment banking to manufacturing, building an audience through YouTube, and the hard-won lessons of business partnerships. John shares candid perspectives on his major equipment investments, product development strategy, and why focusing on fewer things done well transformed his business. Plus, hear his thoughts on automation, the challenges of balancing passion with profitability, and maintaining work-life balance as an entrepreneur.

Check out SMW's IG @saundersmachineworks

Machine Loan Video - https://www.youtube.com/watch?v=HHdDt7VLhjM

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Help support the podcast ⁠⁠www.patreon.com/withintolerancepodcast⁠

In this episode, I sit down with David Liu, founder of Brittle Fluid, to discuss his fascinating journey from mechanical engineering student to software entrepreneur. David shares his evolution from Harbor Freight mini-mill hobbyist to professional machine shop owner, and his experiences at Neuralink and Atomic Machines. We explore his current ventures creating software tools like Tool Trace and Rocket Brackets that reduce friction in manufacturing workflows, the importance of relationships in the industry, and his vision for the future of US manufacturing. David also offers insights on the value of "sending it" - trying new things without fear - and his philosophy on supporting the machinist community through technology.

Check out Dave's IG @davidliuxyz

And his X at https://x.com/davidliuxyz

Go make some foam at https://www.tooltrace.com/

and some brackets at https://www.rocketbrackets.com/

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Help support the podcast at the link in bio

#instamachinist #withintolerancepodcast

This week, Justin Gray shares exciting updates about Toolpath Labs' new tool recommendation engine and their partnership with Kennametal, while Zap details his frustrating shop power saga and van towing misadventures. We explore the concept of "technical debt" in both software and machine shops, discuss whether location matters when starting a machine business, and debate the merits of various CAM systems. The conversation covers everything from managing customer-supplied materials and appropriate scrap rates to essential non-machining tools for the shop, with each of us offering practical CAM, metrology, and business tips from our experiences.

Check out Justin's IG @justinsgray and Toolpath Labs @toolpathlabs or ⁠https://www.toolpath.com/⁠

Check out Zap's IG @zap.consulting

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From culinary chef to machine shop owner, Rebecca Wolfinger joins me to share her remarkable manufacturing journey. As co-owner of Mil-Spec Manufacturing, Rebecca discusses building a veteran-owned manufacturing business from the ground up, acquiring their first Haas VF4 for just $10,000, and their recent expansion with a Tormach 1500MX robot cell. She describes her experience navigating the machining industry as a woman, her creative WWII-themed rebranding strategy, and how culinary skills translated surprisingly well to lean manufacturing practices. Rebecca also offers candid advice on effective LinkedIn marketing, work-life balance, and the importance of learning every aspect of the business to ensure its longevity.

Check out Rebecca's IG @rebecca.wolfinger and @milspecmanufacturing

Mil-Spec Shop Tour - https://youtu.be/TV6RfVZYX-s

Mil-Spec Rebrand Video - https://youtu.be/60e8bgfELUY

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In this episode, I catch up with Zap after my paternity leave to discuss our recent experiences. Zap shares updates on his whirlwind travels across the country, shop move complications, dental health revelations, and his work on a high-precision linear motor machine. I talk about my new journey into fatherhood, the emotional rollercoaster of the newborn phase, and balancing life. We dive into technical topics like HyperMill automation scripts, Fusion configurations, and optimizing tool libraries. We answer listener questions about time management challenges, machinist education needs, coolant temperature effects on part tolerance, and share our candid thoughts on tool manufacturers' websites. Plus, we discuss how AI tools are changing shop workflow and documentation.

Check out Zap's IG @zap.consulting

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In this episode, I catch up with Zap and Justin Gray to discuss recent developments in our respective worlds. We dive into tool libraries, machine shop organization, and the challenges of running growing businesses. Justin shares insights from Toolpath Labs' recent company gathering and their progress with AI-driven CAM automation. Zap updates us on his consulting work, travel schedule, and his move into a new 4,000 sq ft shop space and acquiring essential equipment. We also explore topics like proper chip management, metrology tips, and the importance of maintaining professional standards in business relationships. Plus, we discuss the value of hands-on experience in machining and ways to bring more youth into manufacturing.

Check out Justin's IG @justinsgray and Toolpath Labs @toolpathlabs or https://www.toolpath.com/

Check out Zap's IG @zap.consulting

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Easton from Moria Manufacturing returns to share updates and challenges since his last visit. We discuss the rapid expansion, new machines like the SC 300, struggles with employee training, and the unexpected costs of scaling up. Easton provides an in-depth look at how they've optimized their turning operations and shares the invaluable lessons learned from a recent fire incident and transitioning from oil to coolant.

Check out Easton's IG @moria_manufacturing

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This week, Zap updates us on several challenges - his search for a new shop space, ongoing van saga, and dealing with a particularly frustrating customer situation. Meanwhile, I discuss my recent HyperMill software purchase and share thoughts on tool organization in Fusion 360. We also dive into standardizing workflows for small shops and the importance of proper thread gauges.

Check out Zap's IG @zap.consulting

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In this episode, I speak with Phil Linscheid, Director of Manufacturing at Hamilton Company, about his journey through the manufacturing industry. Starting as a young manager at Haas Automation to now overseeing a large medical device manufacturing operation, Phil shares insights on managing people, implementing automation, and balancing technical expertise with leadership. He discusses his approach to hiring, developing talent, and the challenges of staying current with rapidly evolving manufacturing technologies, while emphasizing the importance of character over technical expertise in building successful teams. Check out Phil's IG @phillinscheid

and contact him at phil@sendcutsend.com

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Zap joins me this week to discuss recent travels, re-establishing stability, and the importance of relationships in business. We share updates on new projects, machine purchases, and the integration of automation in machining. Plus, we delve into personal health routines and navigating the complexities of business investments and accounts receivable. It's been a busy and transformative period, both professionally and personally!

Check out Zap's IG @zap.consulting

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Help support the podcast www.patreon.com/withintolerancepodcast