Within Tolerance

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-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast

Dylan and Zap dive into the world of innovative machining techniques, discussing everything from $10 aviator safety glasses to advanced tool automation. They share project highlights like a smart coolant-dosing system and the effectiveness of mist collectors. The duo also covers the importance of quality tool investments and the latest trends in workholding systems. Plus, get a peek into their engaging experiences at tech events and the complexities of balancing parenthood with the craft of machining!

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-----------------------------------------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-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast

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-----------------------------------------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 @saundersmachineworksMachine Loan Video - https://www.youtube.com/watch?v=HHdDt7VLhjM-----------------------------------------Help support the podcast ⁠⁠www.patreon.com/withintolerancepodcast⁠

David Liu, founder of Brittle Fluid and former engineer at Neuralink, shares his journey from hobbyist to tech entrepreneur. He discusses innovative tools like Tool Trace and Rocket Brackets that streamline manufacturing workflows. David emphasizes the importance of relationships in the industry and advocates for a 'just send it' mentality, encouraging experimentation without fear. His insights on navigating challenges and supporting the machinist community through technology are both inspiring and impactful.

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-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast

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 @milspecmanufacturingMil-Spec Shop Tour - https://youtu.be/TV6RfVZYX-sMil-Spec Rebrand Video - https://youtu.be/60e8bgfELUY-----------------------------------------Help support the podcast ⁠www.patreon.com/withintolerancepodcast⁠

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-----------------------------------------Help support the podcast www.patreon.com/withintolerancepodcast