In this episode, host Dan Alford welcomes back Nathan Sumrall, Welding Engineer at Superior Cladding, for a deep dive into the creativity required to survive and thrive in modern manufacturing. Nathan reveals how his team "tricks" standard robotic systems into performing complex, "off-label" applications—like welding massive conical parts with explosion-bonded Monel—that the machines were never originally designed to handle.

Beyond the shop floor, the conversation shifts to the high-octane world of desert racing. Nathan shares stories from his side hustle, "Good Mayhem Racing," and discusses how building race trucks for the Baja 1000 parallels the problem-solving skills needed in welding engineering. From diversifying Houston’s economy beyond oil and gas to revising the American Welding Society’s handbook, this episode explores how the next generation of engineers is redefining the industry.

Key Topics Discussed:

"Off-Label" Automation: How Superior Cladding used an ARC 5i system (designed for bores) to successfully weld complex cones and long-radius elbows.

The Science of Dissimilar Metals: Technical insights on welding Monel to steel using nickel buffer layers to prevent hot cracking.

Good Mayhem Racing: Nathan’s passion for desert racing and how he applies engineering principles to build race-ready Toyota 4Runners.

The "Replacement" Myth: Why robots handle the "dark, dirty, and dangerous" jobs to upskill workers rather than replace them.

Diversifying Manufacturing: Moving beyond the "oil patch" into aerospace, defense, and marine sectors (including submarines and icebreakers).

The LeTourneau Legacy: The shared educational roots of Dan and Nathan at LeTourneau University and the philosophy of "no big jobs, only small machines."

Guest Bio: Nathan Sumrall is a Welding Engineer at Superior Cladding in Houston, Texas. A graduate of LeTourneau University, he specializes in corrosion-resistant alloy welding and parametric programming. He creates custom solutions for the oil and gas, aerospace, and defense industries and currently chairs an AWS committee revising the handbook on clad and dissimilar metal welding.

In this episode of The Roboticist Chronicles, host Dan Allford sits down with mechanical engineering student Jaxon Baker, a repeat guest on the podcast. Jaxon, a rising senior, discusses his involvement with the Formula SAE and Baja SAE programs, which Allford considers to be highly valuable extracurricular activities. The programs allow students to gain hands-on engineering and design experience by building race cars from raw materials.

Jaxon shares details about the Baja team's successful season, which included bringing home the first Baja trophy in A&M program history after a third-place finish in the acceleration event. He also discusses the team's "catastrophic failure" during the endurance event, where the back half of the chassis sheared off due to fatigue. Both Dan and Jaxon highlight this failure as a crucial learning experience that can't be replicated in a classroom setting.

Looking ahead, Jaxon talks about his new role as suspension lead for the Formula team and their plans to innovate with a decoupled suspension system. The team is also preparing for an invitational competition in Rome, and their goal is to win a ninth national title.

The conversation also touches on Jaxon's career aspirations, his shift in focus away from professional automotive racing, and the reasons for it, including the desire for a better work-life balance and a more performance-focused design role. He also discusses some of the classes he is looking forward to, including a compressed air systems class and an automotive engineering class.

Want to learn more?

Support the A&M Formula team by visiting their website or social media pages to learn how you can help them reach their goals for the upcoming season. 

Have a  Link ECU, or  dampers you'd like to donate? The team is in need of sponsorships for their upcoming season. 

Contact Jaxon here.

In this episode of The Roboticist Chronicles, host Dan Allford of ARC Specialties welcomes Tom Fuhlbrigge and Carlos Martinez from Scalable Robotics. Discover their innovative vision-based system that allows users to simply "show" a robot what to do, eliminating complex programming. Learn how this technology is transforming processes like welding, cladding, and cold spray, making them more accessible and efficient for welders and other skilled trades. Tom and Carlos share insights from their extensive careers in robotics, including their time at ABB , and explain how their system uses 3D scanning and intuitive interfaces to simplify robot operation. They also discuss the different machine vision technologies, the evolving costs of cameras, and why making robots easier to use is crucial for widespread adoption in manufacturing.

Watch the Episode Here!

Join Dan Allford and John Martin of ARC Specialties as they reveal "The Dark Side of Machine Building" – the often-unseen struggles of failed automation projects. They discuss the prevalence of expensive, non-functional robots that end up collecting dust, and the financial burden on customers who might pay multiple times for a system that still doesn't work. This episode dives into the challenges of rebuilding poorly configured robotic cells, including issues with incorrect robot setup, I/O, and costly software options. Learn why ARC Specialties, as a certified integrator through the Association for the Advancement of Automation (A3), emphasizes rigorous standards, safety plans, and adherence to codes to ensure quality and prevent such nightmares. They also offer advice to end-users on vetting integrators and the importance of specialized expertise in automation. Discover why, despite the difficulties, ARC Specialties always finishes a project, even if it means not always making a profit.

 Join Dan Allford and Johnny Tyler live from the Offshore Technology Conference (OTC) in Houston, Texas, in May 2025, as they delve into the surprising high-tech nature of the event, showcasing how robotics and automation are revolutionizing the oil and gas industry and beyond. Discover ARC Specialties' groundbreaking offshore robotic riser system and other innovative robots like the "BatBot" for plasma cutting and welding, and the versatile "#BeerBot," while also hearing about their marketing efforts and upcoming showcase at Automate in Detroit for advanced additive manufacturing. They also emphasize the enduring value of trade shows for networking and business growth, despite the challenges of the past few years. 

Join Dan Allford as he speaks with @Bart Taylor, the driving force behind the Greater Houston Manufacturers Association (GHMA). They discuss Bart's journey from media to championing local manufacturing, the untapped potential of Houston's industrial ecosystem, and the GHMA's vision for connecting and promoting the region's makers to a national and global audience.

Greater Houston Manufacturing Association

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Join us for an in-depth look at Welding Consultants, LLC., a leading provider of welding inspection and nondestructive testing services. In this episode, we sit down with Matthew Brinkman, VP of Operations and Senior Welding Engineer, to  explore the company's history, delve into the intricacies of various testing methods, and discuss the critical role of quality control in ensuring the safety and reliability of critical infrastructure.

Key Highlights:

• Learn about the different types of nondestructive testing techniques, including ultrasonic testing, eddy current testing, and magnetic particle testing.
• Discover the importance of destructive testing in qualifying welding procedures and ensuring the integrity of critical components.
• Witness the advancements in technology, including the use of CNC machines and automated micro-hardness testers, that have revolutionized the testing process.
• Gain insights into the challenges and opportunities facing the welding inspection industry.

This video provides a comprehensive overview of the essential role played by Welding Consultants in ensuring the safety and reliability of critical infrastructure across various industries. Join us for an in-depth look at Welding Consultants, Inc., a leading provider of welding inspection and nondestructive testing services. In this episode, we explore the company's history, delve into the intricacies of various testing methods, and discuss the critical role of quality control in ensuring the safety and reliability of critical infrastructure.

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"Welding Consultants LLC is unique in the welding and quality assurance industry because it is the first organization directed by degreed and licensed welding engineers. Supporting WC’s engineering effort are qualified NDE technicians who provide a full range of quality-related services. From welding and specification design through in-process QC to final quality verification, WC provides the customer with a myriad of services—all from a single source."

• Welding Inspection and Nondestructive Examination
• Mechanical Testing of Welds
• Specialized Testing Services
• Procedure and Performance Qualification
• Welding Engineering
• Technical Training and Training Aids

Calling all future automotive engineers! This episode dives into the world of Baja SAE with Jackson Baker, a sophomore mechanical engineering student at Texas A&M. Jackson recently served as chief engineer for his university's Baja team, leading the design and construction of an off-road vehicle to compete in a grueling endurance race.

Tune in to hear Jackson discuss:

• His internship experience working with Dan Alford at Arc Specialties.
• The challenges and triumphs of leading a Baja SAE team.
• How his team's car performed, achieving an impressive 18th place finish overall and 4th in design.
• His plans to return as chief engineer next year.

This episode is packed with inspiration for any student interested in automotive engineering or design competitions. Get ready to get dirty and learn what it takes to succeed in Baja SAE!

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In this episode of the Roboticist Chronicles, your host Dan Allford invites Jean Rabatin, a distinguished industry expert from Yaskawa Motoman, to share her wealth of experience in the realm of robotics and automation. Jean recounts stories from her early days in the field and sheds light on the challenges of integration spanning over two decades. Uncover the fascinating evolution of robotics, examine its influence on employment, and grasp the significance of adaptability. Tune in for a captivating discussion that navigates through the historical, current, and future landscapes of automation.

GET IN TOUCH WITH JEAN RABATIN:
Linkedin: https://www.linkedin.com/in/jean-rabatin-1423558/

ABOUT YASKAWA MOTOMAN

Yaskawa Motoman, established in 1989, stands as a premier robotics company in the Americas. With a global footprint of over 540,000 Motoman robots, 18 million servos, and 30 million inverter drives, Yaskawa offers automation solutions across diverse industries. Their extensive product line includes 150+ robot models and pre-engineered "World" solutions, featuring application-specific work cells. Partnered with sister companies, Yaskawa Motoman is dedicated to delivering top-notch quality, innovation, and customer satisfaction. As a subsidiary of Yaskawa Electric Corporation, a global leader since 1915, Yaskawa Motoman continues to drive automation excellence with a wide range of industrial robots and a commitment to customer success.

For more information, visit Yaskawa Motoman (www.motoman.com)

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