The Roboticist Chronicles

How do you go from designing high school robotics projects to engineering 3D-printed metal gun suppressors before even starting your sophomore year of college? In this episode, host Dan Alford sits down with rising mechanical engineer Jack Wedlake, who turned a $10 investment in self-made metal business cards and a DIY portfolio into real-world manufacturing internships. 

Whether you are a student trying to land your dream internship or an industry professional looking to cultivate raw talent, Jack’s story is a masterclass in relentless initiative, hands-on skill-building, and creating your own career opportunities. 

The $10 Strategy:
How custom metal business cards, a simple website, and sheer persistence landed Jack an internship at Radical Firearms while still in high school. 

3D Printing & Superalloys:
A look into Jack's innovative muzzle break design utilizing destructive interference and laser powder bed fusion.

Small Schools vs. Big Reputation:
Why choosing a smaller university gave Jack immediate, freshman-year access to machine shops, labs, and mentorship.  

If Jack’s story inspired you, please take a moment to subscribe, rate, and review The Roboticist Chronicles on your favorite podcast platform!

WATCH THE VIDEO HERE

Enjoyed this episode? If you found value in this conversation, please consider subscribing, rating, and sharing it with a colleague or fellow engineer!

Links & Resources:

• Host: Dan Allford
• Listen to More Episodes: The Roboticist Chronicles 
• Video Version: Watch on YouTube via the link in the description above.

Thank you for listening to The Roboticist Chronicles — bridging the gap between hands-on engineering and industry innovation.

In this episode of The Roboticist Chronicles, host Dan Allford sits down with Tim Kinnaman, AWS District 1 Director and avid collector of historic welding technology, live from the AWS Welding Summit in The Woodlands, Texas. Together, they explore the rich history of the welding industry, from preserved artifacts like atomic hydrogen welding and early space-welding samples to the evolution of power sources and electrodes. Tim and Dan discuss the vital role of volunteerism within the American Welding Society (AWS), tracing the society’s origins back to World War I, and highlight the immense professional and personal rewards of getting involved in industry organizations.

Key Discussion Points:

• Uncovering Welding History: Dan and Tim reflect on their shared passion for preserving historical welding equipment, highlighting rare museum artifacts like atomic hydrogen welding tools, early space welds, and mid-century heavy-duty electrodes.
• The Legacy & Mission of the AWS: A deep dive into how the American Welding Society was born out of World War I fleet repairs and how its volunteer-driven mission continues to advance the science and application of welding today.
• The Value of Professional Volunteerism: Tim shares his experience as an AWS District Director, emphasizing how getting involved in industry societies offers unmatched networking, continuous learning, and career mentorship.
• Learning from the Past to Build the Future: Exploring how understanding older, manual welding processes and vintage power source variables helps modern engineers troubleshoot and innovate with today's advanced robotics.

Whether you are a seasoned welder, a manufacturing professional, or someone passionate about industrial history, this episode offers a fascinating look at where the industry came from—and the dedicated volunteers keeping its future bright.

WATCH THE EPISODE HERE

Enjoyed this episode? If you found value in this conversation, please consider subscribing, rating, and sharing it with a colleague or fellow engineer!

Links & Resources:

• Host: Dan Allford
• Listen to More Episodes: The Roboticist Chronicles 
• Video Version: Watch on YouTube via the link in the description above.

Thank you for listening to The Roboticist Chronicles — bridging the gap between hands-on engineering and industry innovation.

In this episode of The Roboticist Chronicles, host Dan Allford sits down with high school student Caroline for an exit interview following her two-day job shadowing experience at ARC Specialties. Caroline shares her firsthand impressions after interviewing various team members, ranging from project managers and mechanical engineers to software developers and welding engineers. 

Key Discussion Points:

• Exploring Career Paths: How early exposure helps students differentiate between generalist and specialist engineering routes, including biomedical applications like surgical robotics and prosthetics. 
• Hands-On Learning: Caroline's realization of how hands-on software programming can be, alongside her experiences with her school's all-girls FIRST robotics team, "IronPlaid", and laptop maintenance program. 
• Real-World Exposure: The critical role job shadowing plays in giving students a realistic view of workplace collaboration and technical professions beyond what they can read online. 

Whether you are an educator, a student exploring STEM careers, or an employer interested in hosting shadow programs, this episode highlights the value of giving young people a look into the machine workforce.

WATCH THE EPISODE HERE

Enjoyed this episode? If you found value in this conversation, please consider subscribing, rating, and sharing it with a colleague or fellow engineer!

Links & Resources:

• Host: Dan Allford
• Listen to More Episodes: The Roboticist Chronicles 
• Video Version: Watch on YouTube via the link in the description above.

Thank you for listening to The Roboticist Chronicles — bridging the gap between hands-on engineering and industry innovation.

What does it take to stay relevant in the rapidly evolving world of automation for over two decades? Jose Elizalde shares his transition from a field electrician at Intercontinental Airport to becoming a top-tier designer at ARC Specialties. Discover how a commitment to "paid education" and mastering complex global safety codes can turn a job into a lifelong career of innovation.

The "Insatiable" Mindset

In this episode, Dan Allford sits down with Jose Elizalde to discuss the drive for knowledge required to succeed in modern robotics. Jose reveals the technical hurdles of building machines for 33 different countries, including the nuances of 50Hz versus 60Hz power systems and navigating the stringent A3 robotics safety certification. Beyond the blueprints, Jose shares his personal story—from serving in the U.S. Marine Corps to his latest challenge: conquering the Texas journeyman electrician exam on his first attempt.

Main Takeaways:

• The Value of Certification: Why A3 Robot Integrator certification is a game-changer for safety and record-keeping.
• Global Engineering: Adapting to international standards like IEC and varying electrical frequencies across borders.
• Career Evolution: How to leverage on-the-job learning to move from manual labor to complex system design.
• The "Always in School" Mindset: Why learning CNC, 3D printing, and new codes is essential to avoid falling behind the curve.

Watch the Episode HERE

Enjoyed this episode? If you found value in this conversation, please consider subscribing, rating, and sharing it with a colleague or fellow engineer!

Links & Resources:

• Host: Dan Allford
• Listen to More Episodes: The Roboticist Chronicles 
• Video Version: Watch on YouTube via the link in the description above.

Thank you for listening to The Roboticist Chronicles — bridging the gap between hands-on engineering and industry innovation.

In this episode of The Roboticist Chronicles, host Dan Allford sits down with guests Gregory Culp and Soumya Mitra from Hypertherm, the global leader in plasma cutting technology. The conversation spans over four decades of industry evolution—from Dan’s early days using plasma for "hot taps" at plutonium plants in 1983 to the latest breakthroughs in robotic integration.

Key topics discussed include:

• The History of Innovation: A look back at Hypertherm’s 1966 origins and the legendary PAC 500 water injection system that revolutionized high-speed cutting.
• Zero-Force Machining: How plasma’s lack of physical tool force allows for cutting and gouging without complex fixtures or clamps, enabling more flexible robotic automation.
• High-Definition Evolution: Defining "High-Definition" plasma through ISO ranges and achieving tolerances within 20,000ths of an inch.
• New Technologies: Deep dives into the XPR series, the launch of the Powermax 33 XP, and the highly anticipated Extended Pilot Arc (EPA) technology, which allows robots to initiate cuts even if they initially "miss" the part.
• Solving the "Miserable" Jobs: How automated plasma gouging is replacing the loud, smoky, and carbon-heavy process of manual carbon arc gouging in shipyards and foundries.
• Smart Consumables: The shift toward single-piece cartridges and RFID technology to simplify maintenance and move toward "zero-programing" operations.

Join us for a technical deep dive into why plasma remains an essential, enabling technology for the EV industry, shipbuilding, and heavy manufacturing

Watch the episode: https://youtu.be/Yn835TRYGvg

Enjoyed this episode? If you found value in this conversation, please consider subscribing, rating, and sharing it with a colleague or fellow engineer!

Links & Resources:

• Host: Dan Allford
• Listen to More Episodes: The Roboticist Chronicles 
• Video Version: Watch on YouTube via the link in the description above.

Thank you for listening to The Roboticist Chronicles — bridging the gap between hands-on engineering and industry innovation.

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.

Enjoyed this episode? If you found value in this conversation, please consider subscribing, rating, and sharing it with a colleague or fellow engineer!

Links & Resources:

• Host: Dan Allford
• Listen to More Episodes: The Roboticist Chronicles 
• Video Version: Watch on YouTube via the link in the description above.

Thank you for listening to The Roboticist Chronicles — bridging the gap between hands-on engineering and industry innovation.

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.

Enjoyed this episode? If you found value in this conversation, please consider subscribing, rating, and sharing it with a colleague or fellow engineer!

Links & Resources:

• Host: Dan Allford
• Listen to More Episodes: The Roboticist Chronicles 
• Video Version: Watch on YouTube via the link in the description above.

Thank you for listening to The Roboticist Chronicles — bridging the gap between hands-on engineering and industry innovation.

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!

Enjoyed this episode? If you found value in this conversation, please consider subscribing, rating, and sharing it with a colleague or fellow engineer!

Links & Resources:

• Host: Dan Allford
• Listen to More Episodes: The Roboticist Chronicles 
• Video Version: Watch on YouTube via the link in the description above.

Thank you for listening to The Roboticist Chronicles — bridging the gap between hands-on engineering and industry innovation.

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.

Enjoyed this episode? If you found value in this conversation, please consider subscribing, rating, and sharing it with a colleague or fellow engineer!

Links & Resources:

• Host: Dan Allford
• Listen to More Episodes: The Roboticist Chronicles 
• Video Version: Watch on YouTube via the link in the description above.

Thank you for listening to The Roboticist Chronicles — bridging the gap between hands-on engineering and industry innovation.

 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. 

Enjoyed this episode? If you found value in this conversation, please consider subscribing, rating, and sharing it with a colleague or fellow engineer!

Links & Resources:

• Host: Dan Allford
• Listen to More Episodes: The Roboticist Chronicles 
• Video Version: Watch on YouTube via the link in the description above.

Thank you for listening to The Roboticist Chronicles — bridging the gap between hands-on engineering and industry innovation.