Machinists

Summary

Big Ideas Lab: Episode Summary – "Machinists"

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

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.”

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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.”

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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.

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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.

Transcript

[Narrator]

Precision is an art. And for Drew Hash, that artistic pursuit began in the kitchen. Drew spent 25 years as a chef mastering the subtleties of flavors, heat, timing and technique. Cooking required instinct, focus, and a deep understanding of how the smallest adjustments could transform a dish. He later took his craft outside the kitchen and poured these skills into the art of knife making. Making knives required patience, discipline and an obsession with detail. Each blade had to have the perfect balance and grip, movement effortlessly through ingredients and hold up to years of use. This process demanded the same precision he had mastered in cooking, where small adjustments made the difference between good and exceptional. Then Drew's pursuit of precision opened the door to something even greater. He stepped into the world of machining, where measurements became smaller, tolerances tighter, and the demands of precision higher. Drew was driven by the pursuit of perfection and joined the machinists of Lawrence Livermore National Laboratory, crafting some of the most precise objects on earth. Components for fusion research, space exploration, and national security. The same patience, discipline and eye for detail that guided him as a chef and knife maker would now be tested in entirely new ways. Welcome to the Big Ideas Lab. Your weekly exploration inside Lawrence Livermore National Laboratory. Hear untold stories, meet boundary pushing pioneers and get unparalleled access inside the gates. From national security challenges to computing revolutions, discover the innovations that are shaping tomorrow. Today, machinists at Lawrence Livermore shape raw materials into specialized components essential for national security and scientific research. With tools ranging from manual lathes to computer controlled machining systems, they cut, drill and mill with extreme precision, working with titanium, aluminum and specialized alloys. Unlike mass production machining, machinists at the lab craft high precision parts for fusion research and cutting edge science. Blending traditional craftsmanship with advanced technologies like design, digital manufacturing, additive processes and high precision lathes. Some machines have been in use for decades, yet their precision remains unmatched even by modern standards. The 1953 Swiss made jig bore is a tool prized for its accuracy and near perfect alignment of critical components.

[Drew Hash]

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.

[Narrator]

Drew Hash is an apprentice machinist at Lawrence Livermore National Laboratory, training through the Machinist Apprenticeship program, a rigorous four year course designed to develop the next generation of precision machinists. The program combines classroom instruction with hands on experience, exposing apprentices to a wide range of machining techniques and technologies. Working with lab mentors, machinists rotate through different machine shops, gaining expertise in precision milling, turning and grinding, to name a few. Beyond technical skills, the program emphasizes problem solving and independent thinking. Preparing apprentices to work on high stakes projects. But machining wasn't Drew's first career.

[Drew Hash]

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.

[Narrator]

His path eventually led him to machining at the lab, A place where machinists have a long standing reputation for doing extraordinary work.

[Drew Hash]

Machinists at the lab were legendary through the years. Like they did crazy stuff, so I was aware of it.

[Narrator]

That reputation, along with his growing interest in machining, shaped his view of the trade.

[Drew Hash]

I was intrigued by machinists, but I didn't know a lot about them. Old school photos you see of them in their coats, wearing a shirt and tie underneath. Stand next to a monstrous machine in 1950. No eye protection. Even as an apprentice, we get a lot of freedom to come up with processes to get the job done on our own. 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. There's a lot of troubleshooting and problem solving involved, similar to cooking, similar to knife making.

[Narrator]

Also, Drew's path to machining was unconventional. Every machinist, regardless of how they enter the field, shares a common commitment to to precision and craftsmanship.

[Drew Hash]

Our responsibility is to make these parts from prints for the sake of our customers. And they need to be 100% perfect. The problem is, how do we do that as quickly and efficiently as possible?

[Narrator]

At Lawrence Livermore, machinists work from highly detailed engineering blueprints that specify every dimension, tolerance and material requirement. Each one a blueprint for transforming raw materials into flawless, functional parts. Don Hill is a senior machinist at Lawrence Livermore Labs.

[Don Hill]

The apprenticeship itself is pretty competitive to get into. They don't just take anybody. They want people with experience.

[Narrator]

The apprentice program, one of California's most prestigious such programs and a fixture at Lawrence Livermore since 1954, trains machinists to meet the lab's unique manufacturing needs. Far from the industry standard, machining requires technical expertise and a deep understanding of how materials are shaped and refined. Transforming raw materials into precise components is intricate and highly specialized.

[Don Hill]

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. There's actually about a dozen different machine shops throughout the lab and they all serve different purposes. I work in smmf, Special Materials Machining facility. We do a lot of exotics, more parts that are specific to the mission of the lab.

[Narrator]

Exotics are metals like titanium, vanadium, tantalum, and specialized alloys. Materials known for their strength, heat resistance and precision requirements. These metals are essential for the lab's advanced research and national security projects. Working with these specialized materials often requires creativity and problem solving. Machinists must find the best approach, sometimes using the latest technology and other times relying on time tested methods that have been around for decades.

[Drew Hash]

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.

[Narrator]

Machining is about problem solving at the highest level. The work at the lab is highly specialized and supports projects from fusion research at the National Ignition Facility to precision optics for space telescopes. Every project presents a unique challenge, requiring technical skill and creative problem solving to shape material materials that push the limits of engineering.

[Drew Hash]

I think the scale that we work at, as far as size is pretty mind blowing that most people can't wrap their head around. Even me. Sometimes I'm like, I can't believe how minute that measurement is. We're dealing in sometime millionths of an inch. How even big is that?

[Narrator]

Machinists must constantly adjust for variables like heat, material stress, and even microscopic imperfections that could impact the final product.

[Don Hill]

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. There's things we can use, like how flat a part is before and after I've machined it. The roundness of the part before and after I've machined it, that will tell me if it's getting too much stress in it if it's moving around too much. So I'm keeping track of that.

[Narrator]

This level of precision is about following measurements and understanding how materials respond under stress. Hands on experience and instinct also play a vital role.

[Drew Hash]

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.

[Narrator]

The role of machinists is constantly evolving. With new challenges and new opportunities emerging, machinists at Lawrence Livermore are shaping the future of precision manufacturing, using machine learning to optimize tool paths, reduce material waste, and improve accuracy.

[Drew Hash]

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.

[Narrator]

The ability to troubleshoot, problem solve and adjust to real time challenges is something no algorithm can replace.

[Drew Hash]

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.

[Narrator]

Machining at Lawrence Livermore is a critical responsibility. Every component they craft contributes to a larger mission.

[Don Hill]

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.

[Narrator]

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. Thank you for tuning in to Big Ideas Lab. If you loved what you heard, please let us know by leaving a rating and review. And if you haven't already, don't forget to hit the Follow or Subscribe button in your podcast app to keep up with our latest episodes thanks for listening.