From Microns To Megastructures: Machining At The Extreme Ends Of The Spectrum, 472 Making Chips Podcast For Manufacturing Leaders podcast

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From Microns to Megastructures: Machining at the Extreme Ends of the Spectrum, 472

19h ago 55:39

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What do a luxury wristwatch and a 50-foot-long aerospace weldment have in common? They’re both precision-machined, but that’s where the similarities end.

In this episode of MakingChips, we’re exploring the extremes of manufacturing—from parts that fit on the tip of your finger to parts so massive they require cranes and riggers just to load onto a machine.

Paul Van Metre and Mike Payne are joined by two guests who represent the far ends of the machining scale. Josh Hacko, a fourth-generation watchmaker from Sydney, Australia, crafts ultra-small and ultra-precise components for timepieces and high-tech applications like quantum computing and medical implants.

On the other end, Jerry from Baker Industries in Michigan oversees the fabrication and machining of massive weldments and structural components for aerospace, defense, and nuclear energy—some measuring over 50 feet and weighing tens of tons.

This episode dives deep into the radically different strategies each shop uses for tooling, fixturing, inspection, quoting, and problem-solving. From tea strainers used to sort microscopic parts to massive additive weld builds handled by 30-ton cranes, it’s a fascinating look at how scale transforms every aspect of the job.

If you’ve ever wondered how much machining can vary across the industry, this conversation will expand your view. Whether you're cutting parts measured in microns or managing five-ton setups, one thing remains constant: it’s all about having the right people who love the craft.

Segments

(0:00) Why the people behind the process matter most—no matter the scale
(0:26) How Paperless Parts can simplify quoting in your shop
(2:16) Comparing the biggest and smallest jobs in machining
(4:30) Josh Hacko’s background in watchmaking and micro part production
(6:03) Jerry Kablak’s work on large-scale machining for aerospace, energy, and defense
(6:51) Part sizes: from sub-millimeter to over 70 feet long
(8:38) How Josh got into contract micro-manufacturing by accident
(11:53) Handling tiny parts: bar diameters under 2mm and parts smaller than a fingerprint
(13:45) How Jerry and his team navigate some of the largest projects in the world
(19:28) Josh’s creative solutions: glue workholding, sieves, acetone, and hand-ground tweezers
(22:19) Logistics challenges in big machining: setup time, crane handling, and laser tracking
(26:16) Leverage Hire MFG Leaders to equip your shop
(28:22) Handling and inspection of tiny parts: from tea strainers to plastic tweezers
(32:16) Overproduction and scrap on both sides of the spectrum
(33:54) Inspection: From laser trackers to 700x optical zoom on a Zeiss CMM
(36:14) Tolerances: Josh works in single-digit microns; Jerry works in 10–20 thou over 40 feet
(44:05) Drilling a 20-micron hole and the tools it takes to do it
(45:29) Your success depends on the skill and resilience of your people
(47:34) From rocket hardware to medical implants to lunar landers
(51:08) Mutual respect across the size divide
(54:11) Listen to Machine Shop Mastery if you’re serious about growing your shop

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