Within Tolerance

Episode two digs into presets to boost throughput in CAM. Justin and Zap break down the golden rule—if you're dialing in feeds and speeds every single program, you need a preset—plus how far the rabbit hole goes with floor finishing, wall finishing, tape-and-glue, and everything in between. Plus why the same carbide in a different holder isn't the same tool at all. Check out Zap's IG @...

Kicking off Down the Rabbit Hole, a new Within Tolerance podcast for nerds, by nerds. Justin and Zap launch their multi-part series "My Tool Library Is Better Than Yours" with the bootstrap basics: a simple four-folder structure, modeling your holders and tools accurately, and getting roughing and finishing presets dialed in. No money required—just stop building tools from scratch every...

Justin Gray catches us up on life post-Toolpath. We get into Justin Gray Labs and his vibe coding kits — along with the security nightmares they're built to prevent. He's also chasing fidget pistons to a two-tenth window on a Syil and Speedio. Then we get into Kinematic Sauce, the calibration algorithm he and Zap built for Speedios, with Fanuc and Haas next. Plus, his new show Down the Rab...

Two months of catching up with Zap: the Toolpath Summit recap, his Claude-built ERP CritLink processing real money, and his Boise shop dialed in for remote operation. Dylan finally has power, runs the Flex overnight, untangles a kinematic shift on the C250, and survives a titanium job that tried to take him out. Check out Zap's IG @zap.consulting ----------------------------------------- Help...

Matt Blackwell spent over two decades fixing jets and flying C-17s before building a one-man backyard shop and a fiber laser fixture business he never planned on. We talk spindle gripping lessons, the messy line between hobby and business, and how a guy in a backyard shop ends up tapping a few hundred thousand holes. Check out Matt's IG @blackwell_engineering ----------------------------------...

Joe Alonso tells the full Novo Modo origin story—off-grid childhood, working full-time at 16, a career detour through blindness and Microsoft, and launching a shop on pure conviction with no customers lined up. We dig into his inspection-first approach, keeping shops small on purpose, and why culture fixes more than training ever will. Check out Joe's LinkedIn at linkedin.com/in/joseph-alonso-...

Zap and Dylan catch up after a busy stretch. Boise expansion, Texas customer visits, QuickBooks meltdown, and the Claude Code build. Dylan's still chasing power for the Flex, doubled up compressors, and is increasingly frustrated with Fusion. Plus questions on specialization, work holding, financing, and the worst shops Zap's walked into. Check out Zap's IG @zap.consulting ------------...

Brian Kippen is back after nearly four years to talk about an incredible period of growth and change at KAD Models. From teaching machining to acquiring a wire forming business, adding a MAM with automation, and managing three facilities across two coasts—all while raising a toddler. We dive into the cultural challenges of bringing precision work to a fast-paced prototype shop, the reality of mach...

Zap and I wrap up 2025 with our first live podcast! Patreon members join us as we answer questions, reflect on 2025, and talk about plans for 2026. Thanks to everyone for a wonderful 2025 and looking forward to a great 2026 with more guests and episodes! McMaster Ugly Sweater - https://laurenfahey.me/mmc-ugly-christmas-sweater/ Keyence Sensors are - FR-S01 for radar level sensing and FI-C20D for r...

This week I talk with Ethan Perrin about MIT Formula SAE, building the Miters West shop, and why a small fiber laser and press brake changed how he prototypes. We also hit rescuing CMM's on a budget and his alumni EV formula car. Check out Ethan’s IG @ethan.perrin97 ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast

In‑person catch‑up: pre‑Flex rigging shuffle, neighbors bribed with donuts, and the first HyperMill customer part. Zap runs through leaving Boise, growing the team, splitting work the right way, and getting a shop moving with CMM, coolant, and probing. Check out Zap's IG @zap.consulting ----------------------------------------- Help support the podcast www.patreon.com/withintolerancepodcast

We catch up on a busy stretch: Zap’s UK stint, dialing in systems, and turning chaos into consistency—including saying no when it counts. Dylan locks the shop layout, keeps the S700, preps for the Hermle HSFlex and hyperMill, and shares a few hard-won long-cycle lessons. Justin's Speedio Filter - https://marketplace.sendcutsend.com/p/CD80E306/chip-filtering-grate-filter-for-brother-speedio-s50...

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 ---------------------...

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 ----------------------------------------- Help support the podcast www...

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-expen...

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 ----------------------------------------- Help support the podcast www.pat...

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.”...

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 mac...

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 pl...

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 creatio...

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 p...

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...

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...

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 R...

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...