The Roboticist Chronicles

What does it take to stay relevant in the rapidly evolving world of automation for over two decades? Jose Elizalde shares his transition from a field electrician at Intercontinental Airport to becoming a top-tier designer at ARC Specialties. Discover how a commitment to "paid education" and mastering complex global safety codes can turn a job into a lifelong career of innovation.The "Insatiable" Mindset"You don’t just show up to a place and bring value by just showing up. You bring value because you learn something, and then you bring something to the company, and that brings value to yourself. And that’s what they pay you for." — Jose Elizalde In this episode, Dan Allford sits down with Jose Elizalde to discuss the drive for knowledge required to succeed in modern robotics. Jose reveals the technical hurdles of building machines for 33 different countries, including the nuances of 50Hz versus 60Hz power systems and navigating the stringent A3 robotics safety certification. Beyond the blueprints, Jose shares his personal story—from serving in the U.S. Marine Corps to his latest challenge: conquering the Texas journeyman electrician exam on his first attempt.Main Takeaways:The Value of Certification: Why A3 Robot Integrator certification is a game-changer for safety and record-keeping.Global Engineering: Adapting to international standards like IEC and varying electrical frequencies across borders.Career Evolution: How to leverage on-the-job learning to move from manual labor to complex system design.The "Always in School" Mindset: Why learning CNC, 3D printing, and new codes is essential to avoid falling behind the curve.Watch the Episode HERE

In this episode of The Roboticist Chronicles, host Dan Allford sits down with guests Gregory Culp and Soumya Mitra from Hypertherm, the global leader in plasma cutting technology. The conversation spans over four decades of industry evolution—from Dan’s early days using plasma for "hot taps" at plutonium plants in 1983 to the latest breakthroughs in robotic integration.Key topics discussed include:The History of Innovation: A look back at Hypertherm’s 1966 origins and the legendary PAC 500 water injection system that revolutionized high-speed cutting.Zero-Force Machining: How plasma’s lack of physical tool force allows for cutting and gouging without complex fixtures or clamps, enabling more flexible robotic automation.High-Definition Evolution: Defining "High-Definition" plasma through ISO ranges and achieving tolerances within 20,000ths of an inch.New Technologies: Deep dives into the XPR series, the launch of the Powermax 33 XP, and the highly anticipated Extended Pilot Arc (EPA) technology, which allows robots to initiate cuts even if they initially "miss" the part.Solving the "Miserable" Jobs: How automated plasma gouging is replacing the loud, smoky, and carbon-heavy process of manual carbon arc gouging in shipyards and foundries.Smart Consumables: The shift toward single-piece cartridges and RFID technology to simplify maintenance and move toward "zero-programing" operations.Join us for a technical deep dive into why plasma remains an essential, enabling technology for the EV industry, shipbuilding, and heavy manufacturingWatch the episode: https://youtu.be/Yn835TRYGvg

In this episode, host Dan Alford welcomes back Nathan Sumrall, Welding Engineer at Superior Cladding, for a deep dive into the creativity required to survive and thrive in modern manufacturing. Nathan reveals how his team "tricks" standard robotic systems into performing complex, "off-label" applications—like welding massive conical parts with explosion-bonded Monel—that the machines were never originally designed to handle.Beyond the shop floor, the conversation shifts to the high-octane world of desert racing. Nathan shares stories from his side hustle, "Good Mayhem Racing," and discusses how building race trucks for the Baja 1000 parallels the problem-solving skills needed in welding engineering. From diversifying Houston’s economy beyond oil and gas to revising the American Welding Society’s handbook, this episode explores how the next generation of engineers is redefining the industry.Key Topics Discussed:"Off-Label" Automation: How Superior Cladding used an ARC 5i system (designed for bores) to successfully weld complex cones and long-radius elbows.The Science of Dissimilar Metals: Technical insights on welding Monel to steel using nickel buffer layers to prevent hot cracking.Good Mayhem Racing: Nathan’s passion for desert racing and how he applies engineering principles to build race-ready Toyota 4Runners.The "Replacement" Myth: Why robots handle the "dark, dirty, and dangerous" jobs to upskill workers rather than replace them.Diversifying Manufacturing: Moving beyond the "oil patch" into aerospace, defense, and marine sectors (including submarines and icebreakers).The LeTourneau Legacy: The shared educational roots of Dan and Nathan at LeTourneau University and the philosophy of "no big jobs, only small machines."Guest Bio: Nathan Sumrall is a Welding Engineer at Superior Cladding in Houston, Texas. A graduate of LeTourneau University, he specializes in corrosion-resistant alloy welding and parametric programming. He creates custom solutions for the oil and gas, aerospace, and defense industries and currently chairs an AWS committee revising the handbook on clad and dissimilar metal welding.

In this episode of The Roboticist Chronicles, host Dan Allford sits down with mechanical engineering student Jaxon Baker, a repeat guest on the podcast. Jaxon, a rising senior, discusses his involvement with the Formula SAE and Baja SAE programs, which Allford considers to be highly valuable extracurricular activities. The programs allow students to gain hands-on engineering and design experience by building race cars from raw materials.Jaxon shares details about the Baja team's successful season, which included bringing home the first Baja trophy in A&M program history after a third-place finish in the acceleration event. He also discusses the team's "catastrophic failure" during the endurance event, where the back half of the chassis sheared off due to fatigue. Both Dan and Jaxon highlight this failure as a crucial learning experience that can't be replicated in a classroom setting.Looking ahead, Jaxon talks about his new role as suspension lead for the Formula team and their plans to innovate with a decoupled suspension system. The team is also preparing for an invitational competition in Rome, and their goal is to win a ninth national title.The conversation also touches on Jaxon's career aspirations, his shift in focus away from professional automotive racing, and the reasons for it, including the desire for a better work-life balance and a more performance-focused design role. He also discusses some of the classes he is looking forward to, including a compressed air systems class and an automotive engineering class.Want to learn more?Support the A&M Formula team by visiting their website or social media pages to learn how you can help them reach their goals for the upcoming season. Have a  Link ECU, or  dampers you'd like to donate? The team is in need of sponsorships for their upcoming season. Contact Jaxon here.

In this episode of The Roboticist Chronicles, host Dan Allford of ARC Specialties welcomes Tom Fuhlbrigge and Carlos Martinez from Scalable Robotics. Discover their innovative vision-based system that allows users to simply "show" a robot what to do, eliminating complex programming. Learn how this technology is transforming processes like welding, cladding, and cold spray, making them more accessible and efficient for welders and other skilled trades. Tom and Carlos share insights from their extensive careers in robotics, including their time at ABB , and explain how their system uses 3D scanning and intuitive interfaces to simplify robot operation. They also discuss the different machine vision technologies, the evolving costs of cameras, and why making robots easier to use is crucial for widespread adoption in manufacturing.Watch the Episode Here!

Join Dan Allford and John Martin of ARC Specialties as they reveal "The Dark Side of Machine Building" – the often-unseen struggles of failed automation projects. They discuss the prevalence of expensive, non-functional robots that end up collecting dust, and the financial burden on customers who might pay multiple times for a system that still doesn't work. This episode dives into the challenges of rebuilding poorly configured robotic cells, including issues with incorrect robot setup, I/O, and costly software options. Learn why ARC Specialties, as a certified integrator through the Association for the Advancement of Automation (A3), emphasizes rigorous standards, safety plans, and adherence to codes to ensure quality and prevent such nightmares. They also offer advice to end-users on vetting integrators and the importance of specialized expertise in automation. Discover why, despite the difficulties, ARC Specialties always finishes a project, even if it means not always making a profit.

 Join Dan Allford and Johnny Tyler live from the Offshore Technology Conference (OTC) in Houston, Texas, in May 2025, as they delve into the surprising high-tech nature of the event, showcasing how robotics and automation are revolutionizing the oil and gas industry and beyond. Discover ARC Specialties' groundbreaking offshore robotic riser system and other innovative robots like the "BatBot" for plasma cutting and welding, and the versatile "#BeerBot," while also hearing about their marketing efforts and upcoming showcase at Automate in Detroit for advanced additive manufacturing. They also emphasize the enduring value of trade shows for networking and business growth, despite the challenges of the past few years. 

Join Dan Allford as he speaks with @Bart Taylor, the driving force behind the Greater Houston Manufacturers Association (GHMA). They discuss Bart's journey from media to championing local manufacturing, the untapped potential of Houston's industrial ecosystem, and the GHMA's vision for connecting and promoting the region's makers to a national and global audience.Greater Houston Manufacturing AssociationView The Episode Here

Join us for an in-depth look at Welding Consultants, LLC., a leading provider of welding inspection and nondestructive testing services. In this episode, we sit down with Matthew Brinkman, VP of Operations and Senior Welding Engineer, to  explore the company's history, delve into the intricacies of various testing methods, and discuss the critical role of quality control in ensuring the safety and reliability of critical infrastructure.Key Highlights:Learn about the different types of nondestructive testing techniques, including ultrasonic testing, eddy current testing, and magnetic particle testing.Discover the importance of destructive testing in qualifying welding procedures and ensuring the integrity of critical components.Witness the advancements in technology, including the use of CNC machines and automated micro-hardness testers, that have revolutionized the testing process.Gain insights into the challenges and opportunities facing the welding inspection industry.This video provides a comprehensive overview of the essential role played by Welding Consultants in ensuring the safety and reliability of critical infrastructure across various industries. Join us for an in-depth look at Welding Consultants, Inc., a leading provider of welding inspection and nondestructive testing services. In this episode, we explore the company's history, delve into the intricacies of various testing methods, and discuss the critical role of quality control in ensuring the safety and reliability of critical infrastructure.-----------------"Welding Consultants LLC is unique in the welding and quality assurance industry because it is the first organization directed by degreed and licensed welding engineers. Supporting WC’s engineering effort are qualified NDE technicians who provide a full range of quality-related services. From welding and specification design through in-process QC to final quality verification, WC provides the customer with a myriad of services—all from a single source."Welding Inspection and Nondestructive ExaminationMechanical Testing of WeldsSpecialized Testing ServicesProcedure and Performance QualificationWelding EngineeringTechnical Training and Training Aids

Calling all future automotive engineers! This episode dives into the world of Baja SAE with Jackson Baker, a sophomore mechanical engineering student at Texas A&M. Jackson recently served as chief engineer for his university's Baja team, leading the design and construction of an off-road vehicle to compete in a grueling endurance race.Tune in to hear Jackson discuss:His internship experience working with Dan Alford at Arc Specialties.The challenges and triumphs of leading a Baja SAE team.How his team's car performed, achieving an impressive 18th place finish overall and 4th in design.His plans to return as chief engineer next year.This episode is packed with inspiration for any student interested in automotive engineering or design competitions. Get ready to get dirty and learn what it takes to succeed in Baja SAE!Watch the Video

In this episode of the Roboticist Chronicles, your host Dan Allford invites Jean Rabatin, a distinguished industry expert from Yaskawa Motoman, to share her wealth of experience in the realm of robotics and automation. Jean recounts stories from her early days in the field and sheds light on the challenges of integration spanning over two decades. Uncover the fascinating evolution of robotics, examine its influence on employment, and grasp the significance of adaptability. Tune in for a captivating discussion that navigates through the historical, current, and future landscapes of automation.GET IN TOUCH WITH JEAN RABATIN:Linkedin: https://www.linkedin.com/in/jean-rabatin-1423558/ABOUT YASKAWA MOTOMANYaskawa Motoman, established in 1989, stands as a premier robotics company in the Americas. With a global footprint of over 540,000 Motoman robots, 18 million servos, and 30 million inverter drives, Yaskawa offers automation solutions across diverse industries. Their extensive product line includes 150+ robot models and pre-engineered "World" solutions, featuring application-specific work cells. Partnered with sister companies, Yaskawa Motoman is dedicated to delivering top-notch quality, innovation, and customer satisfaction. As a subsidiary of Yaskawa Electric Corporation, a global leader since 1915, Yaskawa Motoman continues to drive automation excellence with a wide range of industrial robots and a commitment to customer success.For more information, visit Yaskawa Motoman (www.motoman.com)Watch the Video Here

Join us on a thrilling adventure as The Roboticist Chronicles Podcast hits the road! In this special episode, we're on location at the FABTECH Expo in Chicago's McCormick Place, immersing ourselves in the world of welding technology. Johnny Tyler and Dan Allford take you through the expo, reuniting with old acquaintances and forging new connections, all while uncovering the latest innovations in the field.Special thanks to the industry leaders who shared their insights: Maximiliano Falcone from PushCorp, Michael Sharpe from FANUC America Corporation, Tom McElligott from ATI Industrial Automation, Charlie Adams from KUKA, Bob Rochelle from the Gudel Group, Douglas Hixon from ABB, and Sam Noland from Miller Electric Mfg. LLC.Don't miss out on this exclusive behind-the-scenes look at the future of welding technology! Subscribe now and share your thoughts with us.Watch this episode here!

Join us for an extraordinary episode recorded live at Fab Tech 2023 in Chicago! We're honored to host the legendary Sam Kiser, a friend, and mentor in the world of welding. Sam recently clinched the prestigious Laurence Savage Award for his groundbreaking work, and he's here to share his incredible journey.In this episode, Sam unveils the fascinating story behind his award-winning invention, the Inc l 52 rms s t a, a game-changer in welding technology. From battling ductility deep cracking to finding innovative solutions using tantalum and nickel alloys, Sam's expertise shines through over six decades of dedication.Get ready for a captivating conversation with a true pioneer in the field. Sam's wealth of knowledge and passion for metallurgy will leave you inspired and informed. Don't miss out on this deep dive into the logical world of alloys, elements, and the marvels of metallurgy.Watch the Video Here

Welcome to The Roboticist Chronicles, where we bring you stories of innovation in robotics and automation.   In this episode, we welcome Esteban Vazquez to the podcast. Esteban wears many hats at ARC Specialties being a welder, fitter, and now installation tech.  We dive into Estaban's blossoming career and talk about what its like being a "Dreamer" in America.Watch the Video

Welcome to The Roboticist Chronicles, where we bring you stories of innovation in robotics and automation. In this episode, we're on location at OTC 2023 in Houston, Texas, one of the largest oil and gas conferences in the world.Joining us today is Bryan O'Neil, the Director of Global Offshore & Power Generation Segments  at Lincoln Electric, a company that is leading the charge in additive manufacturing. Bryan will discuss how Lincoln Electric's additive solutions are transforming the manufacturing industry and driving innovation in the oil and gas sector.Later in the episode, we'll be joined by Patrick Boster, PE of Stress Engineering Services, a company that specializes in advanced engineering solutions. Pat will take a deep dive into the additive solutions that Lincoln and Stress Engineering are working on together and how they are revolutionizing the way we think about manufacturing.From cutting-edge technology to real-world applications, this episode of The Roboticist Chronicles is not to be missed. Tune in to learn more about the exciting world of additive manufacturing and how it's shaping the future of robotics and automation.Watch the Video!

From the floor of the Offshore Technology Conference in Houston, TX. Dan Allford is joined by Matt Gresens , Sr. District Manager at FANUC America Corporation.

We are joined by Ryan T. Zboril, CEO of Pitts & Spitts. Pitts & Spitts is an American fabrication that shop that focuses on smokers and grills. Pitts & Spitts offers a full family of products including traditional offset smokers, wood pellet grills, charcoal grills, travel grills, combination pits, fire pits and much more. To help you achieve BBQ greatness, we also offer high quality wood pellets, a line of Texas spices, and other high quality, handpicked accessories.Check out Video Here

 We join Stuart Shepherd at the #HowToRobot booth at Fabtech 2022 in Atlanta, GA. to discuss how #HowToRobot is connecting those in the market for robotic solutions to the large network of robot suppliers who can help get the job done. Check out the video here.

 In this episode of The Roboticist Chronicles, Todd Buster, president of Horizon Development & Construction, stops by H.A.T. Studio to discuss commercial building on this installment of Dan's Business Secrets. 

In this episode of The Roboticist Chronicles, Chris Tomlinson, columnist for the Houston Chronicle, stops by H.A.T. Studio to discuss journalism on this installment of Dan's Business Secrets.

In this episode of The Roboticist Chronicles, Aaron Lloyd, Managing Attorney at Lloyd & Lorkowski, PLLC, stops by H.A.T. Studio to discuss corporate law on this installment of Dan's Business Secrets.

In this episode of The Roboticist Chronicles, Dan Allford jumps into The Wayback Machine, joined by an old colleague, Wayne Mausbach P.E.. Follow along as they reminisce on how they met, competing for work in the rock bit industry, past technologies, and other memories.

In this episode of The Roboticist Chronicles, Barrett J. Gibson, of Colliers-International, stops by H.A.T. Studio to discuss the purchasing of commercial real estate on this installment of Dan's Business Secrets.

In this episode of The Roboticist Chronicles, we take a trip to downtown Houston where we visit John S. Egbert of Egbert, McDaniel & Swartz. John joins Dan for this installment of Dan's Business Secrets to discuss patent law. John and Dan have been in business with each other for well over 25 years cumulating in four patents and two trademarks.  

The Roboticist Chronicles Podcast: Dan's Business Secrets Episode 00I have been an entrepreneur since 1983. Historically 90% of start-ups fail. I have yet to bankrupt one (knock on wood). People ask me how I did it. So we are going to do a series on Dan's Business Secrets or Dan's BS for short.Since I learn from others I will have numerous guests on the podcast. I will host experts on leadership, banking, insurance, law, technology, and even how to buy electricity. All of them are both friends and mentors. They will share with you the same things they taught me.But this first episode is my laundry list, stream of consciousness catalog of topics that I plan on exploring in future episodes.I hope you enjoy it. When you are 64 years old I hope you will have as many good memories of struggles, successes, and failures as I have.ARC Specialties thrives on problems, send us yours!- Dan Allford

Join your favorite roboticist as he sits down with Bruce Arnold, President of Advanced American Technology Inc..  Advanced American Technology does government contracting with the Department of Defense. Bruce Arnold, originally from Orange, Texas, has many years of experience in manufacturing engineering.

Dan Allford welcomes Trey Parrish of Bird Dog Solutions LLC. to the team in today's episode. Trey Parrish' Owner/President of Bird Dog Industrial Solutions LLC., has been in or around the welding industry for 20+ years and met Dan during a company turn-around on the west coast. This merger will help ARC Specialties introduce more automation into the oil and gas industry.Trey ParrishMobile: 803-448-4510Email: [email protected] Johnny Tyler ([email protected]) if you are interested in being a guest on The Roboticist Chronicles.

This episode of The Roboticist Chronicles is brought to you from the show floor of FABTECH 2021 in Chicago, Illinois. Dan sits down with his fellow exhibitors, BUG-O Systems, ATI, and XIRIS Automation, and discusses the tradeshow's state since the pandemic and what new exciting products and initiatives are on the horizon.

On this week’s episode of The Roboticist Chronicles, Dan Allford is joined by Matthew Brinkman, President of Welding Consultants LLC.. 

On this week’s episode of The Roboticist Chronicles, Dan Allford is joined by Cameron Serles, President of XIRIS Automation, Inc... As they talk about the history of arc video monitoring, the various technical applications involved, and how XIRIS does it differently, and why it is better.

Join Gary Kowalski, Senior District Manager at FANUC AMERICA, and Dan Allford, President of ARC Specialties, as they reminisce on some of their past projects. They will go over some of their failure, successes, and proudest achievements in the robotics industry.

What is good fit-up? And why is it crucial to the success of a welding project?Dan Allford, President of ARC Specialties and the host of Roboticist Chronicles, meets with Dave Hebble, ARC Specialties’ Technical Services Manager, to expand on the idea of fit-up and explain it to the rest of the company. The two have worked together since the late 70s, with Hebble acting as Allford’s mentor ever since.You can trace a lot of robotic system failures to poorly fitted parts, explain Allford.“With machining, you impose your will on the part. You take the part and you remove everything you don’t want… In welding, the part imposes its will on you. In other words, the shape of the part we can’t change – we just have to deal with it.”Hebble also touched on defining the scope and flow of a welding project before getting started on it. “What is good fit up?” he asked. “Good fit up means something different to each person, so before you start, that needs to be defined.”Allford added that, to him, fit up meant three things: joint accuracy, fixture accuracy and robot accuracy. All of those things could potentially add even more confusion to the process, emphasizing the importance of defining the flow.“Before you can figure out which problem to fix, you’ve got to figure out which problem you have,” he said.Subscribe to ARC Specialties’ Roboticist Chronicles podcast to learn more about the nuts and bolts of robots, automation, and the implications of an evolving machine workforce.

Because they deal primarily with physical products, anyone in manufacturing knows that the industry as a whole has taken a hit from the effects of the pandemic. “But COVID isn’t the only crisis that has occurred in the robotics industry,” revealed Robert Little, Founder, and CEO of ATI. “What people are not familiar with is the decline in automotive since 2017 – a decline worldwide in the investment in automotive robotics.”

Oh boy. Now they’ve really gone and done it. Arc Specialties President Dan Allford always enjoys getting a little spicy on The Roboticist Chronicles, but in this edition it’s a full-on spirited debate with host Tyler Kern. You may have heard back-and-forth about lockdowns, which most nations have implemented during the COVID-19 pandemic to stem the spread of the deadly virus, but very few started with a three-pawed lion in Zambia.

Johnny Tyler, Marketing and Design Specialist at Arc Specialties, has seen many companies adopt an unambitious marketing strategy – or, worse, not even draw out a strategy at all – rather than invest resources in something that can make even a small company a globally known name in the internet age.

Every business approaches how they work in a unique way. Each has a philosophy and culture, and each approach has its merits; some more successful than others. But why? On this episode of The Roboticist Chronicles, we talked business philosophy with Dan Allford, president of ARC Specialties.ARC Specialties has sound technology, but they still need a corporate structure to execute it. Allford, who had years of technical training but only one business class, wanted to create something that worked at ARC Specialties. Instead of reading books on the latest fads, he followed people. And one that inspired him the most was Lockheed Martin’s founder Kelly Johnson and his Skunk Works philosophy.What is Skunk Works? It is the name of Lockheed’s Advanced Development Program and has become a business philosophy applied to many, many industries. It’s based around creating groups within an organization and allowing them a high degree of autonomy.“What I appreciate about Johnson and Skunk Works is that it’s about empowering project managers and giving them the ability to control their destiny," Allford said.While working in automation and robotics, you might assume that it isn’t people-centered. The human portion, or the "team," is the most significant part according to Allford.“We reward people based on what they create, not who they manage,” he said. “A good manager hires the right people, gives them a task, tools, resources and lets them do what they do best.”That’s how ARC Specialties runs, stripping out layers of bureaucracy and focusing on the task. It also allows the company to remain nimble in the marketplace and exchange ideas. It even allows Allford's employees to tell him when he’s wrong!

From its inception in 1983 to now, ARC Specialties has become a case study in the growth of an American entrepreneurial endeavor. Company President Dan Allford took the business out of a garage and has since turned the automated manufacturing systems provider into an international enterprise. On the first episode of The Roboticist Chronicles, host Tyler Kern sat down with Allford to explore the history of ARC Specialties and analyze how its trials and tribulations reflect growth and challenges within the industry. Continuity and steady growth kept ARC on an upward trajectory over the decades, and Allford said that sometimes it is not about what a company does, but what it does not do. “As long as you keep your mistakes commensurate with the size of your business, you’ll survive. So, while we were small, we made small mistakes, and we survived,” Allford said. ARC has endured the globalization of manufacturing which has seen jobs leave the United States, but Allford said the industry is entering a renaissance in America today. Certainly, that is a welcome sight to Allford, who after almost forty years still has an unwavering passion for welding and manufacturing. “I still like building things,” he said. “The only thing better than building something is building something that builds something.” After creating jobs in more than 20 countries, Allford’s greatest build may not be a product but an exemplary company.

As integrated solutions like automation, robotics, and process development become more and more integrated in the manufacturing industry, we decided to sit down with Dan Allford, President of ARC Specialties, to get some insight on his industry and break down just why “manufacturing became cool again.”