TechnologyBusinessManagementEntrepreneurship

Next-Gen Metal Fab

Fabricators and Manufacturers Association

Next-Gen Metal Fab explores where metal fabrication and manufacturing are headed. Hosted by The Fabricator’s Tim Heston alongside rotating industry co-hosts, the podcast examines the impact of automation, software, and emerging technologies across today’s fab shops. Part of the FMA Podcast Network.

Play

Open in

22 episodes
monthly
Avg 46 min
English

Episodes 22

Newest Oldest Longest

All20 Unplayed20 In progress0 Played0

Counted on this page — what you have heard stays on this device, so it is not something the list can be paged by.

October 2 · 1 hr 4 min
Developing better managers and leaders in metal fabrication
On this episode of Next-Gen Metal Fab, The Fabricator Senior Editor Tim Heston and business advisor Mark Ernst, a longtime member of the Fabricators and Manufacturers Association (FMA) and its Management Advisory Council, examine one of the biggest challenges facing growing metal fabrication shops: developing the people and management structure needed to keep up with the business. They discuss management training, evolving org charts, automation, career paths, and performance expectations as shops grow and change. For more on this subject, check out Mark’s FMA webinar, Managing Difficult People, on Nov. 4, focused on handling behavioral and performance issues before they damage morale and workplace culture. Email Tim at podcast@fmamfg.org with any comments or questions.
September 2 · 50 min
Where does venture capital see investment opportunity in metal fabrication?
Why is so much new investment flowing into metal fabrication? Tim Heston of The Fabricator, Caleb Chamberlain of OSH Cut, and Lance Thrailkill of All Metals Fabricating discuss venture capital, automation, consolidation, digital manufacturing, and whether new tech-driven business models are a threat or an opportunity for traditional fab shops. Email Tim at podcast@fmamfg.org with any comments or questions.
July 16 · 57 min
Estimating and quoting for competitive advantage with Jason Ray
Estimating and quoting are no longer just about pricing parts. They're strategic tools that help metal fabricators and other manufacturers win the right work, improve profitability, and build more efficient operations. In this episode of Next-Gen Metal Fab, Tim Heston talks with Jason Ray, co-founder of Paperless Parts, about defining an ideal part profile, improving costing accuracy, activity-based costing, prototype versus production pricing, process mapping, and where AI fits into the future of estimating and quoting. Email Tim at podcast@fmamfg.org with any comments or questions. And learn more about Paperless Parts.
June 16 · 48 min
The new economics of online sheet metal fabrication
Jonathan Sessa of Fabworks joins Tim Heston and co-host Caleb Chamberlain of OSH Cut to discuss how online manufacturing platforms are reshaping sheet metal fabrication. Fabworks grew out of Ventura, Calif.-based Sessa Manufacturing, a third-generation family fab business founded in 1980. Inspired in part by the success of OSH Cut and SendCutSend, Sessa shares how his family business transformed into a highly automated, software-driven operation focused on instant quoting, rapid turnaround times, and exceptional customer service. The conversation explores AI, automation, software development, and the changing economics of modern manufacturing. Email Tim at podcast@fmamfg.org with any comments or questions. And learn more about Paperless Parts. Learn more about Fabworks and Sessa Manufacturing.
May 7 · 1 hr 8 min
Bridging tribal knowledge and tech in fabrication with Jay Phillips
In this episode of Next-Gen Metal Fab, host Tim Heston talks with Jay Phillips of Fresno, Calif.-based Valley Iron Inc. about the future of workforce development, shop culture, and technology in metal fabrication. Phillips explains why modern fab shops can no longer rely solely on tribal knowledge as experienced workers retire and manufacturing becomes more software-driven. The conversation covers hiring and onboarding, leadership development, cross-training, lean manufacturing, shop-floor communication, safety culture, and the growing need to connect programmers and machine operators. They also discuss how fabrication companies can better engage younger workers through digital tools, simulation, mentorship, and hands-on problem-solving, while still preserving the practical knowledge that keeps shops running. As chairman of the Fabricators and Manufacturers Association (FMA), Phillips also shares how initiatives like SparkForce are helping attract and develop the next generation of manufacturing talent. Comments, questions, or sponsorship opportunities: podcast@fmamfg.org. Learn more about FMA and SparkForce.
April 15 · 57 min
Quoting, estimating, and costing in sheet metal fabrication
In this episode of Next-Gen Metal Fab, Tim Heston talks with Cody Lee and Lance Thrailkill about quoting, estimating, and costing in modern sheet metal fabrication. They break down how shops are using software, data, and work center–based costing to improve accuracy and consistency, while navigating challenges like material volatility, PPAP requirements, and scheduling constraints. The conversation also touches on AI, automation, and how estimating connects everything from pricing to production strategy. Email Tim at podcast@fmamfg.org with any comments or questions. And learn more about Paperless Parts.
March 18 · 46 min
Digitizing information and AI in the changing job shop with Sunny Han
In this episode of the Next-Gen Metal Fab Podcast, host Tim Heston speaks with Sunny Han, FMA member and founder of Fulcrum, about the role digitized information plays in preparing fabrication shops for adopting AI. Tim and Sunny discuss how many job shops still rely on spreadsheets, paperwork, and institutional knowledge that lives in people’s heads, and why before AI can deliver meaningful insight, that information must be digitized and accessible. Sunny also talks about how faster information flow and real-time analysis could reshape how shops quote work, schedule production, analyze profitability, and respond to changing market conditions. The conversation also explores the risks of information loss as experienced workers retire and why improving data visibility may become a key competitive advantage for fabrication companies. In this episode: Why “information waste” still slows many job shops Why digitization is essential before AI can help manufacturers How AI could change quoting, scheduling, and job costing The risk of tribal knowledge disappearing as experienced workers retire What the future may look like for distributed manufacturing Comments, questions, or sponsorship opportunities: podcast@fmamfg.org. Learn more about FMA memberships.
February 13 · 45 min
Optimizing production scheduling in metal fabrication
In this episode of Next-Gen Metal Fab, Tim Heston is joined by Caleb Chamberlain of OSH Cut and Lance Thrailkill of All Metals Fabricating to talk production scheduling, software investments, and growth strategy. They break down what a recent Fabricators and Manufacturers Association survey says about automation trends, why scheduling and ERP tools are becoming critical, and how shops are tackling WIP, queue times, and real-world bottlenecks. The conversation also covers using Monte Carlo simulation to model scheduling outcomes, the growing role of AI-driven tools in programming and planning, and what’s ahead for 2026 in terms of capacity, technology, and expansion. Email Tim at podcast@fmamfg.org with any comments or questions.
January 16 · 52 min
Scaling a multigenerational fabrication business with Matthew Nix
In this episode of Next-Gen Metal Fab, host Tim Heston is joined by special guest Matthew Nix of Nix Companies, along with OSH Cut co-founder Caleb Chamberlain, for a wide-ranging discussion on how very different fabrication business models can succeed. Nix, an FMA member and fifth-generation leader of Nix Industrial, shares how a traditional family-owned manufacturer scaled through acquisitions, systems, and leadership development. Chamberlain explains how OSH Cut was built as a software-first fabrication company designed to handle high-mix, low-volume work at scale. Together, the group compares approaches to growth, customer onboarding, talent development, metrics, and culture, offering practical insights for fabricators navigating change and uncertainty. Email Tim at podcast@fmamfg.org with any comments or questions.
Dec 11, 2025 · 48 min
Evaluating 2025 and building smarter fab shop strategies for 2026
In this year-end episode of Next-Gen Metal Fab, Tim Heston sits down with All Metals Fabricating’s Lance Thrailkill and OSH Cut CEO Caleb Chamberlain to unpack a wildly unpredictable 2025 in metal fabrication. Lance shares how a flat year suddenly surged in Q4 (driven by data centers, telecom, and a surprise spike in WIP) while investing in five-axis machining, automation, and AI-driven programming. Caleb explains OSH Cut’s record-breaking growth, the balancing act of running an on-demand model, and why capacity, lead times, and recession planning all collide in ways most shops underestimate. The conversation dives into scheduling pitfalls, tube-bending innovation, lights-out realities, ERP limitations, tooling shortages, and how both leaders think about resilience heading into 2026. It’s a candid look at strategy in a volatile market—and why breaking old models might be the smartest move for the year ahead. Email Tim at podcast@fmamfg.org with any comments or questions.
Oct 21, 2025 · 40 min
The emergence of private equity and vibe coding in fabrication
In this episode of Next-Gen Metal Fab, we break down the biggest trends and takeaways from this year’s FABTECH. From the surge of cobots and advanced automation tools on display to the practical challenges of integrating and maintaining them, the show revealed just how fast the industry is evolving. We also dig into the wave of private equity interest sweeping through the fragmented fabrication sector and what it really takes to scale these businesses successfully. Plus, we explore how vibe coding, AI-powered software and large language models could disrupt traditional B2B platforms, and why laser welding is emerging as a key productivity driver for high-mix job shops. Email Tim at podcast@fmamfg.org with any comments or questions. And learn more about Paperless Parts.
Aug 28, 2025 · 43 min
Integrating automation with the right people in manufacturing
In this episode of Next-Gen Metal Fab, Lance Thrailkill of All Metals Fabricating joins Tim Heston to talk about becoming the most automated job shop in America. Tim and Lance explore how the the Texas-based job shop is investing in robotic welding, automated laser cutting, punching, and panel bending, while also empowering and training its workforce to embrace change. Hear how leadership builds buy-in, communicates a clear vision, and takes a strategic approach to adding new capabilities. Plus, a look at what’s next as All Metals expands its machine shop and leans into AI and ERP automation to drive the future of manufacturing. Email Tim at podcast@fmamfg.org with any comments or questions. And learn more about Paperless Parts.
Jul 25, 2025 · 42 min
What the future holds for software development in metal fabrication
In this episode, we explore how software, automation, and AI are transforming the metal fabrication industry, from the front office to the shop floor. Guests Caleb Chamberlain of OSH Cut and Cody Lee of Everyday Technologies share how their companies have embraced digital tools to streamline quoting, scheduling, production, and quality control. Caleb explains how OSH Cut has developed custom software solutions that eliminate manual steps and boost efficiency. He also shares his excitement about the future of AI-powered and low-code tools in enabling even more flexible, scalable systems. Cody reflects on his shop’s journey from paper-based processes to an integrated ERP and quoting system, and how this shift has improved responsiveness and visibility into operations. Together, the guests discuss how AI, automation, and digital transformation are reshaping metal fabrication, and why the future will require a balance between rapid innovation and long-term operational stability. Email Tim at podcast@fmamfg.org with any comments or questions. Learn more about Paperless Parts.
Jul 2, 2025 · 39 min
From purchase to progress: Transforming a legacy job shop
On this episode of the Next-Gen Metal Fab podcast, Tim Heston sits down with Cody Lee for a one-on-one conversation about Cody's path the metal fabrication industry. Cody talks about how he took over Everyday Technologies, a Sidney, Ohio-based sheet metal job shop founded in 1928. Faced with an outdated ERP and quoting process, Lee implemented a new ERP system and standardized quoting. The changes improved tracking of costs, labor, and margins, driving shop floor improvements like first article inspections. Lee shares how he’s balanced legacy work with new prototype jobs, and how these upgrades created new roles for employees, shifting them from manual tasks to more analytical, high-impact work. Email Tim at podcast@fmamfg.org with any comments or questions.
May 28, 2025 · 46 min
Practical approaches to using AI in manufacturing and fabrication
In this episode of the Next-Gen Metal Fab podcast, host Tim Heston is joined by Caleb Chamberlain of OSH Cut and Lance Thrailkill of All Metals Fabricating to explore how artificial intelligence is reshaping the metal fabrication and manufacturing industries. As tariffs and reshoring continue to stir uncertainty and volatility, Tim, Caleb, and Lance talk about how fabricators are looking for ways to stay competitive and agile. AI and automation are emerging as powerful tools, with the potential to transform everything from quoting and scheduling to sales and customer service in manufacturing. But implementation isn’t simple—many companies struggle to integrate AI meaningfully due to legacy software and processes. Caleb and Lance share real-world insights into how fabricators can overcome these hurdles and tap into AI’s potential. They also discuss how tools like ChatGPT are democratizing software development, enabling even small shops to create custom applications and make smarter, faster decisions. Email Tim at podcast@fmamfg.org with any comments or questions. Learn more about the 32nd Advanced Laser Applications Workshop (ALAW).
Mar 28, 2025 · 44 min
Understanding the impact of tariffs on metal fabrication businesses
Tim Heston, Lance Thrailkill, Caleb Chamberlain, and Cody Lee discuss how the everchanging tariffs on imported metals have led to significant volatility and price increases, challenges for manufacturers, and domestic mills raising prices to match the tariffs rather than passing along the benefits. They explore strategies for diversifying customer bases, improving operational efficiency, and leveraging technology to streamline sales and quality processes. The conversation highlights the importance of adaptability, value-added services, and forging strong partnerships with customers in the evolving manufacturing landscape. Email Tim at podcast@fmamfg.org with any comments or questions. Learn more about the 2025 FMA Annual Meeting.
Feb 18, 2025 · 1 hr
The wide spectrum of business models in sheet metal fabrication
Cody Lee from Everyday Technologies and Lance Thrailkill from All Metals Fabricating join the Next-Gen Metal Fab and Tim Heston as new co-hosts with Caleb Chamberlain from OSH Cut. The discussion touches on the history and evolution of their businesses, the role of automation and software in improving efficiency and productivity, and the various models and trends emerging in the metal manufacturing industry. Tim, Caleb, Cody, and Lance also talk about the evolving landscape of the industry, including the potential for symbiotic relationships between different types of sheet metal fabrication businesses, and the shift in mindset from focusing on machine productivity to optimizing the entire production flow. Email Tim at podcast@fmamfg.org with any comments or questions. Learn more about the 2025 FMA Annual Meeting.
Nov 26, 2024 · 35 min
Finding new ways to grow business in metal fabrication
In this episode, Tim Heston and Caleb Chamberlain dive into the future of custom metal fabrication, exploring what the next several years could hold for this ever-evolving industry. They discuss how technology, particularly software and AI, is reshaping the landscape, driving trends like horizontal and vertical integration and paving the way for industry consolidation in metal manufacturing. Email Tim at podcast@fmamfg.org with any comments or questions. Learn more about the 2025 FMA Annual Meeting.
Sep 24, 2024 · 27 min
Strategies for hiring the right metal fabrication shop employee
Tim and Caleb discuss the challenges of hiring and retaining employees in the metal fabrication industry, particularly at high-mix, high-volume fab shops. Caleb talks about how his company has found success by hiring people without prior fabrication experience and training them in-house and focusing on creating a collaborative, positive work environment with clear processes and systems to reduce stress. They also talk about the fact people need livable wages, and without that, workers are going to continue to move from shop to shop. Tim and Caleb also talk about the benefits of cross-training shop floor employees in software development and equipment operation as well as the importance of building a strong, engaged team to support business growth and success. Email Tim and Caleb at podcast@fmamfg.org with any comments or questions. Learn more about the Pipe + Tube Conference.
Jul 24, 2024 · 36 min
Measuring costs and the value of time in metal fabrication
Tim and Caleb discuss cost and time management in metal fabrication and job shop operations. They talk lean manufacturing, cash flow, margins, different approaches to cost accounting, and the importance of managing overhead costs. The conversation also touches on topics such as inventory, direct costs, remnant management, and the use of automation in the fabrication process. They reference two books on the topic: Rebirth of American Industry: A Study of Lean Management by William H. Waddell and Norman Bodek as well as The Monetary Value of Time: Why Traditional Accounting Systems Make Customers Wait by Joyce Warnacut. Email Tim and Caleb at podcast@fmamfg.org with any comments or questions. Learn more about The Fabricator's Tech Summit.

Showing 1–20 of 22 episodes