Within Tolerance

Latest Episodes:

Within Tolerance Episode 278 - Post Summit Clarity with Zap Jun 08, 2026

Show notes

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

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Help support the podcast www.patreon.com/withintolerancepodcast

Within Tolerance Episode 277 - Matt Blackwell of Blackwell Engineering May 01, 2026

Show notes

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

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Help support the podcast www.patreon.com/withintolerancepodcast

Within Tolerance Episode 276 - Joseph Alonso of Novo Modo Apr 11, 2026

Show notes

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-34874690Check out Novo Modo's IG @novomodomachining

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Help support the podcast www.patreon.com/withintolerancepodcast

Within Tolerance Episode 275 - Still Powerless with Zap Mar 31, 2026

Show notes

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

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Help support the podcast www.patreon.com/withintolerancepodcast

Within Tolerance Episode 274 - Brian Kippen of KAD Models Mar 06, 2026

Show notes

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 machine automation ROI, and why delegation is harder than it sounds.

Check out Brian's IG @kadmodels

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Help support the podcast www.patreon.com/withintolerancepodcast

Within Tolerance Episode 273 - Wrapping Up 2025 With Zap Feb 13, 2026

Show notes

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 refractometer

Check out Zap's IG @zap.consulting

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Help support the podcast www.patreon.com/withintolerancepodcast

Within Tolerance Episode 272 - Ethan Perrin Jan 21, 2026

Show notes

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

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Help support the podcast www.patreon.com/withintolerancepodcast

Within Tolerance Episode 271 - Pre-Flexing with Zap Dec 20, 2025

Show notes

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

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Help support the podcast www.patreon.com/withintolerancepodcast

Within Tolerance Episode 270 - Wait, You Take Breaks? With Zap Nov 14, 2025

Show notes

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-s500-and-s700 Check out Zap's IG @zap.consulting

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Help support the podcast www.patreon.com/withintolerancepodcast

Within Tolerance Episode 269 - Devin Bodony of Lichen Precision Oct 31, 2025

Show notes

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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Help support the podcast www.patreon.com/withintolerancepodcast

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