Big Ideas Lab: Episode Summary – "Machinists"

Release Date: April 1, 2025
Host/Author: Mission.org
Podcast: Big Ideas Lab

Introduction

In the "Machinists" episode of Big Ideas Lab, Mission.org delves into the intricate world of machinists at Lawrence Livermore National Laboratory (LLNL). This episode spotlights the meticulous craftsmanship and advanced technology employed by these professionals, highlighting their critical role in national security and scientific research.

Drew Hash: From Chef to Master Machinist

Narrator (00:05): The episode opens by introducing Drew Hash, whose journey from a 25-year career as a chef to a skilled machinist underscores a profound pursuit of precision. Drew's culinary expertise in flavors, heat, and technique seamlessly transitioned into knife making, emphasizing his innate attention to detail and dedication to perfection.

Drew Hash (03:34): “They say it's the most accurate machine in the lab. So it was an absolute pleasure to work on this machine while also being kind of scary because I didn't want to crash it.”

Drew’s transition to machining at LLNL represents a significant shift towards higher precision and complexity, as he begins crafting components essential for fusion research, space exploration, and national security.

The Machinist Apprenticeship Program

Narrator (03:42): Drew is currently enrolled in LLNL’s rigorous Machinist Apprenticeship Program, a four-year course blending classroom instruction with hands-on experience. Apprentices rotate through various machine shops, mastering techniques like precision milling, turning, and grinding under the mentorship of seasoned machinists.

Drew Hash (04:31): “I was a chef for 25 years and I got burned on that. And I transitioned into knife making. Knife making was sort of my retirement plan, and it ended up snowballing into something that was a lot of fun and very popular.”

Drew’s unconventional path showcases the diverse backgrounds that machinists bring to LLNL, united by a shared commitment to precision and craftsmanship.

Legacy and Reputation at LLNL

Narrator (04:53): LLNL boasts a storied reputation for exceptional machining work, a legacy that Drew found both inspiring and motivating.

Drew Hash (04:53): “Machinists at the lab were legendary through the years. Like they did crazy stuff, so I was aware of it.”

This legacy attracts individuals like Drew, who are driven to contribute to the lab’s high-stakes projects through their expertise.

The Art and Science of Machining

Narrator (05:04): Machining at LLNL involves transforming raw materials into precise components using a blend of traditional craftsmanship and advanced technologies. Machinists work with materials like titanium, aluminum, and specialized alloys, employing both manual and computer-controlled systems to achieve unparalleled precision.

Drew Hash (05:04): “There’s more than one way to skin a cat when it comes to machining. As long as the end goal is met here at the lab, their emphasis on getting it done right, they need it to be perfect. So how you go about doing that is kind of up to me. That's what I enjoy.”

Drew emphasizes the creative freedom within the machining process, highlighting the blend of problem-solving and technical skill required.

Expertise and Specialization

Narrator (07:13): Don Hill, a senior machinist, elaborates on the specialized nature of LLNL’s machining work.

Don Hill (07:13): “You think of 3D printing or even additive manufacturing, where you’re starting with nothing and you’re building material up. We’re kind of the reverse of that. We start with a chunk of material, metal, plastic, whatever, and we’re removing material to make a part out of that.”

Don’s insights reveal the depth of expertise required to work with exotic materials and the multifaceted approach needed to meet LLNL’s unique manufacturing demands.

Problem Solving and Innovation

Narrator (08:21): The machinists at LLNL tackle complex challenges, often requiring innovative solutions and a deep understanding of material properties.

Drew Hash (08:21): “One time we had this job when I worked in the main bay and it was a giant piece of aluminum that was this very odd shape. And they wanted us to cut it up and make these really intricate pieces out of it for them. And everybody was like, how the heck are we going to do this? I ended up using a band saw, which is a pretty crude way to cut up material. It’s the exact same way they would have done it in 1956 or maybe even 1906. Like that technology is still relevant.”

Drew’s anecdote underscores the importance of adaptability and creative problem-solving in machining, even when leveraging traditional methods.

Precision and Technology

Narrator (09:14): Precision is paramount in LLNL’s machining processes, often requiring tolerances measured in millionths of an inch. Machinists must account for variables like heat, material stress, and microscopic imperfections to ensure flawless components.

Don Hill (09:40): “When you’re machining, you’re going to be putting some stress into the material, and stress in the material is going to cause that part to move. And we want the part to not move. We want a perfect part.”

The meticulous attention to detail ensures that every component meets the stringent specifications necessary for LLNL’s cutting-edge projects.

The Human Element in Machining

Narrator (10:06): Beyond following precise measurements, machinists rely on hands-on experience and instinct, particularly when working with manual machines.

Drew Hash (10:17): “One disadvantage of CNC machines, although there are many advantages, is that they don’t have their own intuition right? They don’t know what it feels like. The operator does not know what’s really going on. Whereas on a manual machine you can feel vibrations in the machine and the floor. You hear things, obviously you see things. Sometimes you smell certain things that are a red flag of like, oh, I gotta turn this down.”

Drew highlights the indispensable role of human intuition and sensory feedback in maintaining precision and addressing real-time challenges.

Evolving Roles and Future Prospects

Narrator (10:43): As technology advances, the role of machinists at LLNL is evolving. Innovations like machine learning are being integrated to optimize processes, reduce waste, and enhance accuracy.

Drew Hash (11:02): “The role of a machinist I see changing with the technology, but physics and geometry aren’t going to change. The qualities of material aren’t going to change. The cutting tool technology, I don’t see it changing that much in the near future.”

Drew envisions a future where machinists continue to play a critical role, utilizing their skills to adapt to new technologies while maintaining the foundational principles of machining.

Drew Hash (11:25): “I think the most exciting thing for me is the possibilities are literally infinite. As far as learning, I consider myself the forever student. I will never know it all, and as long as I’m hungry for learning, I can go whichever direction I want. If I want to start making watches, I can do that because I have the skills. If I want to work on parts for space stations or spaceships, I can go do that. The amount of options is very appealing to me and I think just knowing in the back of my head that there’s always going to be something to do and learn.”

Drew’s passion for continuous learning and adaptability reflects the dynamic nature of the machining field at LLNL.

Commitment to the Greater Good

Narrator (12:09): The machinists at LLNL are driven by a sense of purpose, understanding that their work supports significant scientific and national security missions.

Don Hill (12:09): “I believe in the mission, and I like the fact that what I’m doing is also serving what I consider a greater purpose. A greater good perhaps.”

This dedication underscores the profound impact of their craftsmanship on broader societal and scientific advancements.

Conclusion

Machinists at Lawrence Livermore National Laboratory embody the harmonious blend of traditional craftsmanship and modern technology. Through their unwavering commitment to precision, problem-solving, and continuous learning, they contribute significantly to groundbreaking scientific research and national security initiatives. Drew Hash and Don Hill exemplify the passion and expertise that drive LLNL’s machining excellence, showcasing the vital role of human expertise in the age of advanced manufacturing.

Narrator (12:19): “At Lawrence Livermore, machinists are constantly adapting to new materials, techniques, and ways of thinking. For nearly 70 years, these skilled professionals have been the unsung heroes of scientific innovation. And one thing is clear, human expertise is irreplaceable.”

Notable Quotes

• Drew Hash (03:34): “They say it's the most accurate machine in the lab. So it was an absolute pleasure to work on this machine while also being kind of scary because I didn't want to crash it.”

• Drew Hash (05:04): “There’s more than one way to skin a cat when it comes to machining. As long as the end goal is met here at the lab, their emphasis on getting it done right, they need it to be perfect. So how you go about doing that is kind of up to me. That's what I enjoy.”

• Drew Hash (08:21): “One time we had this job when I worked in the main bay and it was a giant piece of aluminum that was this very odd shape. And they wanted us to cut it up and make these really intricate pieces out of it for them. And everybody was like, how the heck are we going to do this? I ended up using a band saw, which is a pretty crude way to cut up material. It’s the exact same way they would have done it in 1956 or maybe even 1906. Like that technology is still relevant.”

• Drew Hash (10:17): “One disadvantage of CNC machines, although there are many advantages, is that they don’t have their own intuition right? They don’t know what it feels like. The operator does not know what’s really going on. Whereas on a manual machine you can feel vibrations in the machine and the floor. You hear things, obviously you see things. Sometimes you smell certain things that are a red flag of like, oh, I gotta turn this down.”

• Drew Hash (11:25): “I think the most exciting thing for me is the possibilities are literally infinite. As far as learning, I consider myself the forever student. I will never know it all, and as long as I’m hungry for learning, I can go whichever direction I want.”

• Don Hill (07:13): “You think of 3D printing or even additive manufacturing, where you’re starting with nothing and you’re building material up. We’re kind of the reverse of that. We start with a chunk of material, metal, plastic, whatever, and we’re removing material to make a part out of that.”

• Don Hill (09:40): “When you’re machining, you’re going to be putting some stress into the material, and stress in the material is going to cause that part to move. And we want the part to not move. We want a perfect part.”

• Don Hill (12:09): “I believe in the mission, and I like the fact that what I’m doing is also serving what I consider a greater purpose. A greater good perhaps.”

Final Thoughts

The "Machinists" episode of Big Ideas Lab provides a comprehensive look into the meticulous and essential work of machinists at Lawrence Livermore National Laboratory. Through personal stories and expert insights, listeners gain an appreciation for the blend of artistry, technical skill, and dedication that drives innovation and supports critical national missions.

For more insightful episodes and untold stories from Lawrence Livermore National Laboratory, be sure to follow or subscribe to Big Ideas Lab on your preferred podcast platform.