Making Sparks

Matthew Nix and Casey Voelker
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Matthew Nix and I, Casey Voelker, are here to speak to the welding and fabrication industry. And just like MakingChips, we want to equip and inspire while attracting the next generation. Everyone will have some takeaways from MakingSparks.

  1. 3h ago

    He Built a Fiber Laser in His Garage. What does that Means for Fabrication?

    In this episode, I sit down with Travis Mitchell, a full-time creator who has built a flat-sheet fiber laser, tube laser, metal 3D printer, CNC equipment, and more from his garage. Travis did not come from a machine-building background. He started in graphic design, got hooked on 3D printing, and followed that curiosity all the way into building machines most people would assume require an OEM, a factory, and a much larger budget. We dig into what it actually takes to design a DIY fiber laser: starting with the controller, finding compatible components, decoding manuals, studying commercial machines, and iterating through the countless variables that make laser cutting work. Assist gas, focus height, cutting recipes, capacitive sensing, motion control, and support documentation all become part of the puzzle. But this conversation is about more than one guy's wildly ambitious garage. It is about what happens as serious manufacturing capability becomes cheaper, smaller, and more accessible. Travis built his first fiber laser for around $15,000. Now, compact air-cooled machines with real cutting capability are entering the market at similar price points, ready to be delivered instead of assembled piece by piece. For job shops, fabricators, and makers alike, the question is changing. It is no longer just, "Can I get this capability?" It is, "Should I build it, buy it, or rethink what my shop can do?" That gap between industrial equipment and accessible technology is shrinking, and Travis is building right in the middle of it. What's Covered in this Episode (0:00) The capability you can buy or build keeps getting cheaper and more accessible (1:05) Meet Travis Mitchell, the creator building fab machines in his garage (3:35) From graphic design burnout to 3D printing to DIY machine building (7:50) Why accessible tech and working technology stacks are manufacturing's future (8:53) How Travis concepts a machine: start at the brain, then build around it (11:20) Take your shop to the next level with DN Solutions (12:33) Shopping by user manual instead of spec sheet (13:38) Using ChatGPT and Gemini to digest 100-page manuals (and the love-hate reality) (17:50) The first big project: a flat-sheet fiber laser nobody had built on camera (21:21) Why you need to join us at the IMTS Job Shops Workshop on September 15 (22:16) Ordering from China and learning assist gas from a single internet photo (25:53) The love-hate with cheap Chinese parts versus true production machines (27:53) Building the DIY tube laser and solving the chuck and clamping problem (32:08) Tube laser capabilities, and designing around the cost of shipping material (34:54) How can ProShop ERP help you achieve on-time delivery? (36:24) Buying a prosumer Skyfire 1200W air-cooled fiber laser and how it compares to xTool and G-Weike (39:29) Lasers versus plasma, and why nobody wants a water jet in their garage (41:13) The CO2 Galvo build, made with his own shop's machines (43:32) Why fiber lasers need a controller with capacitive height sensing (46:45) A new four-car garage and a plan to build a machine together Resources Mentioned Why you need to join us at IMTS 2026! Eagle Lasers DN Solutions ProShop ERP SendCutSend Connect with Travis Mitchell YouTube: Travis Mitchell (DIY Fiber Laser)

    50 min

  2. Jun 17

    Should You Really Buy That Laser? The Hidden Math Behind Modern Fabrication

    Fiber lasers have completely changed what's possible in metal fabrication, but here's the part nobody puts on the brochure: speed alone doesn't make a shop profitable. In this episode I'm joined by Mike Peterson, owner of Critical Laser and Spire Ranges, for an honest conversation about what it actually takes to run a successful laser cutting and sheet metal business in 2026. Mike's story goes all the way back to 1992, when Critical Laser brought one of the first lasers into Utah, a 1,600-watt Mitsubishi CO2 machine that felt more like magic than manufacturing. Since then he's watched the industry move from slow CO2 cutting to high-powered fiber that can turn an hour-long job into a 15-minute run. But as Mike explains, that kind of speed creates a whole new set of problems around labor, material flow, pricing, training, and capacity. What I appreciated most is that we didn't just geek out on machine specs. We got into ownership lessons, family business dynamics, the pricing mistakes that quietly bleed a shop dry, and the danger of making decisions based on revenue instead of profit. Mike shares how simply understanding his own numbers helped Critical Laser double its net margin without buying a single new machine. We also dug into the big question a lot of manufacturers eventually face: when does it actually make sense to bring laser cutting in-house? Mike's answer might sting a little, but it's the kind of honest advice that can save a business from buying an expensive problem wrapped in a shiny enclosure. If you're outsourcing fabrication, thinking about buying your first laser, or just trying to figure out where your shop is really making money, this one is packed with sparks worth catching. Covered in this Episode (0:00) Switching from 3,500W CO2 to 10,000W fiber cut sheet time from 70 minutes to 15 minutes (1:06) Introducing Mike Peterson and Critical Laser and Spire Ranges (7:11) The ownership evolution: from 5 original owners to Mike becoming the sole owner (9:46) Here's why you need to join us at IMTS 2026! (10:39) The danger of equal ownership: Why a single decision-maker matters for banking, equipment purchases, and major operational moves (14:14) The impact of taking over the books and updating customer pricing (18:12) How fiber lasers changed labor: CO2 needed one operator per machine; fiber requires a team just to unload (22:41) Pierce-to-pierce time: why shuttle time matters as much as cut speed when pricing a job (24:24) Beam-on time goals: Critical Laser targets 80-85% laser utilization across every 10-hour shift (25:30) Daily standup tactical meeting: 15 minutes every morning assigning every team member to specific work centers (27:14) Training young hires with formalized machine certifications, checklists, and hands-on tests (31:25) Hire MFG Leaders (33:40) Certification-based pay: each machine adds $0.25/hr; full certification can stack $10-12/hr in raises (36:10) Spire Ranges: gun range equipment manufacturing acquired March 2020; government, commercial, and private work (40:10) The $1M outsourcing threshold: do not buy your own laser unless you are already spending that with your vendor (45:56) The window well neighbor: why you shouldn't buy a cheap laser (48:53) Fiber laser maintenance is costly, which most people don't know (51:35) Why experienced laser buyers qualify on service first and machine specs second (54:57) Gross revenue vs. net margin and the Inconel job that crushed their cash flow (58:31) Why Critical Laser explains hourly rates and overhead to the whole team (59:29) Factur (1:00:34) How Spire and Critical are growing with government contracts and local relationships (1:07:18) Mike's philosophy of running a shop where everyone works with each other Resources Mentioned Why you need to join us at IMTS 2026! BySoft  SendCutSend SendCutSend and the Future of Manufacturing Hire MFG Leaders Factur Connect with Mike Peterson Connect on LinkedIn Email: mike@critical-laser.com Critical Laser Spire Ranges

    1h 8m

  3. May 6

    From Curiosity to Career: How SparkShop is Building the Next Generation of Makers

    What if the biggest challenge in manufacturing isn't technology, but timing? In this episode of MakingSparks, host Brendon DiVincenzo sits down with Shonali Ditz, co-founder and executive director of SparkShop, to explore a powerful idea: we're trying to solve a talent pipeline problem far too late. Shonali's journey from engineering student to nonprofit founder started with a realization that many in the industry share—there simply aren't enough people entering manufacturing and engineering. But instead of focusing on recruiting at the college or job level, she and her team went upstream… all the way to elementary school. What they've built is a hands-on, curiosity-driven approach that introduces kids to engineering before they ever decide what they "are" or "aren't" good at. This conversation goes beyond STEM buzzwords and into something more fundamental: identity. How do kids see themselves? Do they believe they can solve problems, build things, or think like engineers? Through real-world examples, classroom stories, and practical insights, this episode reveals how early exposure, hands-on learning, and reframing failure can unlock entirely new pathways into manufacturing. For shop owners, leaders, and anyone concerned about the future workforce, this episode is a wake-up call—and a blueprint. Because if you want more skilled people in your shop tomorrow, you may need to start inspiring them when they're ten years old today. Resources Mentioned in this Episode (0:00) Building resilience, teamwork, and emotional skills through hands-on learning (1:17) The challenge of explaining manufacturing to kids (2:11) Shonali's background and discovering hands-on engineering through Formula SAE (5:18) Why you need to join us at IMTS 2026! (6:11) Realizing the talent pipeline problem and the origin of SparkShop (9:50) Making manufacturing engaging and relatable for young minds (13:30) Different motivations that draw people into making and problem-solving (16:21) Labor shortages, limiting beliefs, and the need to rethink hiring barriers (20:10) The evolution of modern manufacturing and workforce expectations (22:00) Why we love using SMW Autoblok for workholding (22:43) Inside the SparkShop model: hands-on, teacher-led STEM curriculum (25:41) Learning through failure and building confidence with early exposure (29:46) Connecting manufacturing to the real world students see every day (34:11) Why you need to listen to the Lights Out podcast (34:36) Teacher feedback and increased engagement from all types of students (36:38) Developing teamwork, empathy, and problem-solving skills (39:24) Long-term impact and expanding the pipeline through high school internships  (42:41) Preparing the next generation for workplace expectations (43:57) Bridging the gap between industry and young talent Resources mentioned on this episode Why you need to join us at IMTS 2026! Why we love using SMW Autoblok for workholding Why you need to listen to the Lights Out podcast Reach out to hello@SparkShop.org to get involved Connect with Brendon DiVincenzo Connect on LinkedIn EAGLE Lasers Connect with MakingSparks Follow on LinkedIn Follow on Instagram MakingSparks website

    49 min

  4. Apr 22

    Passing the Torch: The Next Chapter of MakingSparks

    Change in manufacturing rarely comes quietly—and neither does progress. In this special episode of MakingSparks, longtime hosts Matthew Nix and Casey Velker take a moment to reflect, rewind, and ultimately pass the mic to the next voice of the show: Brendon DiVicenzo. It's not an ending—it's a handoff mid-stride. Matthew and Casey revisit the origin story of MakingSparks, from a short-run idea built around 100x growth to a full-fledged podcast embedded in the MakingChips ecosystem. Along the way, they've built something bigger than episodes—a platform for honest conversations, shared lessons, and a growing community of fabricators willing to pull back the curtain on how they really run their businesses. But like any good shop floor evolution, this transition is rooted in focus. Casey leans deeper into storytelling, culture, and video. Matthew explores new opportunities around family business and leadership. And stepping into the spotlight is Brendon—a manufacturing lifer with deep technical expertise, a front-row seat to shop transformation, and a passion for telling the stories that don't always get told. As the conversation unfolds, the trio digs into what makes this industry so resilient right now—from the rise of automation and AI to the growing investment thesis around "HALO" (Heavy Asset, Low Obsolescence). Through it all, one thing stays constant: manufacturing is still, and always will be, a people-first business. This episode isn't a goodbye. It's a recalibration—and a launch point for what's next. Resources Mentioned in this Episode (0:00) The rise of "HALO" investing and why manufacturing is gaining attention (1:42) Matthew and Casey reveal a major announcement  (4:38) The "why" behind MakingSparks' creation (and it's growth) (7:15) The impact of storytelling and listener feedback (8:11) Casey shares what's next: culture, marketing, and video (11:00) The value of an outsider perspective on the show (13:32) Brendon's background in manufacturing and engineering (18:43) Why people are the most rewarding part of manufacturing (23:19) How automation and technology is leveling the playing field (25:29) How manufacturing skillsets are evolving (continuous learning) (28:44) Brendon's vision for the future: highlighting people (32:57) Technology enhancing—not replacing—the workforce (35:09) Final reflections and gratitude from Matthew, Casey, and Brendon Resources mentioned on this episode MakingSparks: How Technology Drives Innovation on the Other Side of Metalworking Nation, 395 Connect with Brendon DiVincenzo Connect on LinkedIn EAGLE Lasers Connect with MakingSparks Follow on LinkedIn Follow on Instagram MakingSparks website

    40 min

  5. Mar 25

    The Hard Truth About Pricing Your Work

    In this episode, hosts Matthew and Casey sit down with Codie Aljets, owner and artist behind Sage Country Customs, to talk about the realities of building a business around custom metal art. Codie shares how he turned his passion for high-detail metal artwork into a full-time career, the lessons he's learned about pricing creative work, and why relationships, storytelling, and value matter just as much as the craftsmanship itself. From navigating the business side of being an artist to building meaningful pieces that clients will treasure for generations, this conversation dives deep into what it really takes to succeed in the metal art world. In this episode, you'll learn: The hard truth about pricing your work and valuing your time Why many artists and fabricators undervalue what they create How personal relationships drive high-end custom work The role of storytelling and meaning in custom metal art Why word-of-mouth and real-world events often outperform social media How philanthropy and community involvement can grow your brand Why the metal art community is one of the most supportive in the industry Timestamps: 00:01:05 – Introduction to Codie Aljets and Sage Country Customs 00:02:02 – Building a business around high-detail custom metal art 00:05:23 – Why Codie focuses only on art instead of general fabrication 00:08:03 – The business side of being a welding artist 00:09:55 – Building relationships with clients through in-person events 00:12:57 – Using art and philanthropy to give back to the community 00:16:04 – The hard truth about valuing your work and pricing your art 00:20:03 – Creating custom pieces that tell a client's story 00:24:59 – Turning the delivery of art into a full experience for clients 00:31:46 – The supportive community among metal artists and creators 00:38:31 – Advice for artists building a career in custom metalwork Resources: Sage Country Customs (Codie Aljets): https://www.sagecountrycustoms.com/ Follow Codie Aljets on Instagram: https://www.instagram.com/sagecountrycustoms/ Lights Out Podcast by Making Chips: https://makingchips.com/show/lights-out/ Buy the Numbers Podcast by Making Chips: https://makingchips.com/show/buy-the-numbers/ If you're a fabricator, artist, or shop owner trying to build something meaningful with your work, this episode will challenge how you think about value, pricing, and the business behind creativity. Let's keep making sparks. 🔥

    41 min

  6. Mar 11

    What Modern Fabricators Can Learn from Blacksmiths

    *]:pointer-events-auto scroll-mt-[calc(var(--header-height)+min(200px,max(70px,20svh)))]" dir="auto" tabindex="-1" data-turn-id= "request-699dba0e-8290-8325-be67-741e8ca9b6a0-7" data-testid= "conversation-turn-38" data-scroll-anchor="true" data-turn= "assistant"> 🔥 Welcome to Making Sparks, the podcast where we ignite your passion for metal fabrication and fuel your business success! 🔥 In this episode, hosts Matthew and Casey sit down with Will England of England Ironworks to explore what modern fabricators can learn from traditional blacksmithing. From watching steel move like Play-Doh at 2,000 degrees to blending TIG welding with forged elements, Will shares how understanding heat, metallurgy, and material behavior can elevate any fabricator's skill set. The conversation dives into craftsmanship, legacy, credibility, and why pride in your work still matters in a fast-paced manufacturing world. In this episode, you'll learn: What modern fabricators can learn from traditional blacksmithing How understanding heat and metallurgy improves your fabrication skills When to forge, when to weld, and how to balance efficiency with artistry Why credibility has the power to inspire belief How customer collaboration strengthens your work and reputation The importance of craftsmanship that outlives you Why balance matters when turning passion into a profession Timestamps: 00:01:05 – Introduction to Will England and England Ironworks 00:04:30 – How Will got started in blacksmithing 00:10:03 – Balancing architectural fabrication with traditional forge work 00:19:20 – What blacksmithing teaches modern fabricators 00:21:10 – Applying heat and metallurgy to real-world projects 00:29:13 – Credibility, integrity, and customer relationships 00:33:42 – Celebrating blacksmithing tradition and Saint Clement's Day 00:37:15 – Passion, balance, and not turning your sanctuary into a burden Resources: England Ironworks – Follow Will England for traditional blacksmithing and architectural metalwork insights Lights Out Podcast by Making Chips: https://makingchips.com/show/lights-out/ Buy the Numbers Podcast by Making Chips: https://makingchips.com/show/buy-the-numbers/

    43 min

  7. Feb 25

    The Critical Few: How to Focus Your Business for Real Growth

    🔥 Welcome to Making Sparks, the podcast where we ignite your passion for metal fabrication and fuel your business success! 🔥 In this episode, hosts Matthew and Casey sit down with executive coach Brent Rasche to unpack what strategic planning really looks like inside a growing manufacturing business. From shiny object syndrome to identifying the "critical few," this conversation dives deep into why planning isn't a one-time offsite event — it's a discipline that must be exercised consistently. They discuss how to build a leadership rhythm that sticks, why transparency drives alignment, and how to pivot when necessary without abandoning your long-term vision. If you've ever struggled with focus, consistency, or getting your team aligned around what truly matters, this episode will challenge and sharpen your leadership approach. In this episode, you'll learn: Why strategic planning is a muscle — not an event How to identify and protect your "critical few" priorities The difference between discipline and motivation in business execution When and how to adjust your plan without becoming reactive Why scorecards and cadence create clarity across your organization How transparency strengthens leadership and team trust Why building a balanced leadership team prevents blind spots Timestamps: 00:00:19 – Welcome to Making Sparks and introduction of Brent Rasche 00:03:39 – Lessons from automotive manufacturing and business cadence 00:06:29 – Why strategic planning matters (even for opportunistic companies) 00:12:04 – Planning as a muscle, not just an event 00:17:10 – Transparency, alignment, and connecting roles to the bigger picture 00:22:26 – Adjusting the plan without losing the vision 00:34:43 – Simplifying priorities and focusing on the critical few 00:46:55 – Discipline vs. motivation and the compound effect in leadership Resources: Connect with Brent Rasche: https://www.focalpointcoaching.com Follow Brent Rasche on LinkedIn https://www.linkedin.com/in/brent-rasche-focalpoint/ Lights Out Podcast by Making Chips: https://makingchips.com/show/lights-out/ Buy the Numbers Podcast by Making Chips: https://makingchips.com/show/buy-the-numbers/ If you're not making strategic plans, you're not making money. Let's keep building better businesses — and let's make sparks fly. 🔥

    59 min

  8. Jan 28

    The Price of Progress: Investing in Machines, People, and Trust

    🔥 Welcome to Making Sparks, the podcast where we ignite your passion for metal fabrication and fuel your business success! 🔥 In this episode, hosts Matthew and Casey sit down with Rob Sublette of Mountain Man Welding and Fabrication to talk about leadership, ownership transitions, smart investment in equipment, and building a business that thrives on quality and process. In this episode, you'll learn: - Why investing in your business can inspire confidence in your team - How buying the right equipment sets up long-term growth - The importance of balancing financial realities with strategic vision - How transparency with your team strengthens leadership - Why cutting corners hurts your brand and your business culture - How building processes and investing in people creates lasting value - What manufacturers can learn from taking calculated risks outside their comfort zone Timestamps: 00:01:23 – Hosts catch up and set the stage for Rob joining the conversation 00:05:16 – Rob Sublette joins from Denver, CO, and shares his journey 00:15:33 – Discussing leadership and the Six Types of Working Genius 00:24:17 – Transitioning ownership and investing in key equipment 00:29:12 – Budgeting for equipment and planning for business growth 00:37:47 – Leadership strategies for younger teams and investing in company culture Resources: Mountain Man Welding and Fabrication: https://mountainmanwelding.com/ Lights Out Podcast by Making Chips: https://makingchips.com/show/lights-out/ Buy the Numbers Podcast by Making Chips: https://makingchips.com/show/buy-the-numbers/ Follow Rob Sublette and Mountain Man Welding on LinkedIn for insights into quality-driven manufacturing

    42 min
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About

Matthew Nix and I, Casey Voelker, are here to speak to the welding and fabrication industry. And just like MakingChips, we want to equip and inspire while attracting the next generation. Everyone will have some takeaways from MakingSparks.

Information

  • Creator
    Matthew Nix and Casey Voelker
  • Years Active
    2024 - 2026
  • Episodes
    63
  • Rating
    Clean
  • Copyright
    © 2024
  • Show Website
    Making Sparks