DIB Innovators

EP 63 — Method MFG’s Rhys Andersen on Bootstrapping a Machine Shop into Aerospace Manufacturing

When Rhys Andersen, Founder & CEO at Method MFG, moved to Texas with an architecture degree, he never imagined he'd end up machining components for spacesuits and rockets. Yet his journey from welding to founding his company exemplifies the untapped potential in American manufacturing. By combining cutting-edge technology with a focus on upskilling his entire team, Rhys has created a manufacturing environment that more closely resembles a tech company than a traditional machine shop — with white walls, white floors, and sophisticated software driving everything from quoting to production.
 
Rhys also shares with Dave his practical experience building a bootstrapped manufacturing company servicing aerospace and defense clients, including his counterintuitive approach to workforce development and the technologies revolutionizing production. His insights demonstrate why manufacturing's image problem is holding back America's industrial base, and how rebranding machining as the tech profession it truly is could help solve critical workforce shortages.
 
 
Topics discussed:
 
Bootstrapping a capital-intensive manufacturing business by purchasing used equipment at a fraction of the cost for new pieces, while supplementing income through with other work to fund the company's early growth.
The transformation of machining into a tech profession where white-collar programmers operate sophisticated 5-axis equipment and automation cells rather than traditional machine operators.
Creating comprehensive cross-training programs to eliminate single points of failure by ensuring every machinist can program and operate the company's most sophisticated equipment.
Leveraging technology as a multiplier through automation cells with robots that can change their own end effectors to handle everything from small vises to 900 kg pallets for unattended overnight production.
The critical role of process documentation using iPads in the shop to capture setup photos and detailed notes, creating an institutional knowledge repository that prevents "reinventing the wheel" with repeat jobs.
Strategic vertical integration decisions like building an in-house anodizing line to control quality and turnaround times for quick-turn aerospace components rather than relying on external vendors.
Managing complex stress patterns in large aerospace components by creating strategic relief cuts and adapting clamping approaches to ensure finished parts maintain tolerance despite internal material stresses.
The potential of AI-driven programming to automate routine aspects of CAM while allowing machinists to focus on more creative problem-solving and complex machining strategies.
Rebranding manufacturing careers through educational partnerships showing students that modern machining involves sophisticated software, 5-axis programming, and automation rather than traditional manual labor.  

EP 62 — Graham Manufacturing’s Matthew Malone on Why Defense Manufacturing Must Reinvest in IT

President & COO Matthew Malone's journey from solving locomotive failures in Indonesia to leading Graham Manufacturing offers rare insight into how technical expertise transforms into business leadership. In this episode of DIB Innovators, Matthew tells Dave how Graham bridges the innovation gap between rapid-iteration space technology and methodical defense requirements while manufacturing critical components for Columbia-class submarines and Ford-class carriers. His perspective challenges conventional thinking about workforce development, supply chain management, and the often-overlooked IT infrastructure that enables entire organizations to function effectively.
 
Topics discussed:
 
How technical problem-solving skills translate directly to business strategy, with Matthew's background in mechanical engineering enabling both relationship-building and physics-based risk management.
Strategies for convincing rapid-iteration innovators to work within methodical defense frameworks while using advanced computational fluid dynamics to redesign legacy systems.
How connecting 3D design environments directly to production eliminates paper-based processes, enabling much faster concept-to-prototype cycles and more efficient system architecture design.
Implementing apprenticeship programs for machinist development while restructuring teams around complementary strengths rather than searching for individual employees who can do it all. 
Treating suppliers as team members by extending resources, deploying manufacturing engineers to improve their processes, and working with government agencies to secure funding for dual-sourcing critical components.
Managing supply chain risks around rare earth metals for electrification and advanced power electronics, where component differences between vendors can be the difference between product success and failure.
The methodical process of demonstrating value to defense customers, from execution within existing structures to proposing improvements that deliver tangible benefits in cost, lead time, or obsolescence management.
Why many leaders focus exclusively on domain-specific capabilities while neglecting the critical systems that allow hundreds of employees to collaborate effectively across the organization. 

EP 61 — Agile’s Chris Pearson on Mastering Space Propulsion with 3D Printing & Test Innovation

The race to protect America's orbital assets is accelerating, and Agile Space Industries is providing the engines needed for rapid spacecraft maneuverability. In this episode of DIB Innovators, CEO Chris Pearson walks Dave through how decades-old chemical propulsion technology is finding new relevance as Space Force openly prepares for potential conflict in space. Through vertical integration combining additive manufacturing and in-house test facilities, Agile has achieved 50% annual growth, turning a garage operation into a company with $42 million in backlog.
 
Chris also shares his journey from UK space engineer to Colorado-based entrepreneur, building multiple successful companies before taking the helm at Agile. His insights on scaling hardware businesses through strategic funding combinations — from non-dilutive SBIR grants to strategic investments from defense primes — provide a masterclass in defense technology commercialization. As Agile expands with a new facility in Tulsa, Chris also offers candid perspectives on managing the cultural transition from innovative startup to production-focused manufacturer while maintaining the speed that gives them their edge in the market. 
 
Topics discussed:
 
How national security space requirements have shifted from satellite deployment to preparing for potential orbital conflict, creating demand for rapid-maneuverability propulsion.
The technical limitations of electric propulsion for military applications, with chemical propulsion providing the immediate thrust needed for threat response and evasive maneuvers.
Leveraging additive manufacturing to condense propulsion system development cycles from months to days by printing complex. geometries impossible with traditional subtractive manufacturing
Creating vertical integration through in-house test facilities that eliminate industry bottlenecks and enable rapid iteration between design and qualification testing.
Strategic capital raising approach combining non-dilutive funding, strategic investment, and commercial revenue to maintain favorable terms.
Balancing the triple funding strategy of government investment, commercial partner funding, and internal R&D to accelerate commercialization while maintaining IP ownership.
Managing organizational evolution from garage operation to volume manufacturer while retaining innovation speed and preventing analysis paralysis.
Building transparent customer relationships around risk management for first-of-kind space technologies, rather than promising unrealistic certainty in performance.
Diversifying from component supply to full propulsion systems and launch logistics services to capture more of the rapidly expanding space operations value chain.

EP 60 — Bazze’s Samuel Semwangu on How Commercial Intelligence Is Transforming Modern Warfare

Samuel Semwangu, CEO of Bazze, provides his insider perspective on the revolution happening in defense intelligence collection that most Americans aren't seeing. Bazze federates queries across dozens of commercial data vendors, delivering intelligence insights in seconds that previously took days. He also explains why the Ukraine war has become the ultimate proof point for commercial intelligence adoption and why our allies are moving faster than the US in embracing these technologies.
 
Samuel tells Dave his journey from spending a decade in the national security community to now at Bazze, highlighting the evolution of exclusive intelligence collection methods of the early 2000s that are now commercially available. His platform enables defense and intelligence organizations to pay only for the specific data they need rather than purchasing entire datasets that might go unused. Beyond technology, Samuel offers surprising insights into why personnel management systems and misaligned incentives are the true obstacles to defense innovation. 
 
Topics discussed:
 
The transformation of global intelligence gathering through commercially available data that was once exclusive to government agencies, with Bazze enabling access to two dozen commercial data sources through a single platform.
How Ukraine has become the definitive proof point for commercial intelligence adoption, demonstrating how commercially available satellite and cell phone data combined with affordable platforms can neutralize advanced military hardware.
Why US allies are adopting commercial intelligence technologies faster than the US: their budgets are smaller, and they're in the “splash zone" of Russia and China.
The structural problem of defense innovation funding, with only approximately 1% of the defense budget dedicated to innovative companies addressing critical national security challenges.
How the post-WWII personnel management system, with constant rotations and outdated incentives, actively works against innovation adoption in defense and intelligence communities.
The disincentivization of adopting unclassified technologies in intelligence organizations where career advancement is tied to conducting classified operations rather than filling intelligence gaps effectively.
Strategies for crossing the "valley of death" in defense tech by building partnerships with established players like Palantir, Valenvar, and Deloitte who are already embedded with target users.
The evolution of data partner relationships in defense tech, where Bazze provides value by establishing government contracts and paying data providers on a per-query basis, dramatically reducing their customer acquisition costs.
How AI is integrated into every element of Bazze's platform, enabling untrained analysts to accomplish in minutes what experienced analysts previously needed days or weeks to complete.

EP 59 — Lt. Gen. Nahom (USAF, ret) on Why Predictability Matters More Than Money in Military Readiness

In a rapidly changing geopolitical landscape, Lt. Gen. Nahom, (USAF, ret), brings invaluable perspective on how Arctic security, budget realities, and emerging technologies are reshaping military strategy. In this episode of DIB Innovators, Lt. Gen. Nahom offers Dave unique insights into why the Arctic has become a critical frontier for national security while climate change creates new opportunities for competition between major powers. 
 
His experience as the Air Force A8 provides a candid look at why the military struggles to rapidly adopt innovative technologies despite having seemingly large budgets and highlights the difficult trade-offs between maintaining aging fleets and investing in modernization. Lt. Gen. Nahom's firsthand account of the Chinese surveillance balloon incident reveals significant domain awareness gaps in detecting unconventional threats, while his strategic advice for small defense companies — partner directly with combatant commands rather than individual services — offers a practical roadmap for navigating the "valley of death" in defense innovation. 
 
Topics discussed:
How climate change is transforming the Arctic into a strategic battleground as retreating sea ice creates new shipping lanes that cut 10-14 days off transit between Asian and European ports, opening economic opportunities that bring competition and potential crisis.
The misconception about military budgets illustrated through the "pass-through" phenomenon, where intelligence agency funding appears in Air Force numbers but isn't actually controlled by the service, leaving single-digit percentage budget flexibility for innovation.
Why maintaining multiple aging aircraft fleets creates unsustainable weapon system sustainment costs, forcing difficult decisions about vertical fleet cuts to enable modernization.
The domain awareness challenges exposed by the Chinese balloon incident, highlighting gaps in detecting and responding to unconventional threats that don't match traditional expectations of attack vectors.
The cost asymmetry problem in modern warfare where adversaries deploy $1,000 drones that require $500,000 missiles to defeat, necessitating more cost-effective counter-UAS solutions.
Why small defense companies struggle to cross the "valley of death" from initial AFWERX/SBIR funding to program of record, requiring partnerships between combatant commands and OSD to secure additional funding pathways.
The critical need for predictability in maintenance and training schedules for aging fleets, which can dramatically improve aircraft availability and readiness virtually overnight when implemented correctly.
How data integration rather than new platforms will transform warfare by 2030, enabling legacy systems like B-52s to work seamlessly with advanced platforms by closing hundreds if not thousands of kill chains inside a vulnerability period.
The strategic imperative of reducing fleet types from seven distinct fighter fleets to four to cut maintenance and logistics costs while enabling faster modernization.
The contrasting lessons from Ukraine and Israel conflicts versus the "ultimate away game" in the South China Sea, where geographic distances create fundamentally different operational challenges that many technological solutions from current conflicts won't address.

EP 58 — Advanced Space’s Bradley Cheetham on Using Orbital Mechanics to Cut Mission Costs

Advanced Space CEO & President Bradley Cheetham's journey from a PhD student at CU Boulder to successfully putting a satellite around the moon demonstrates how small, innovative companies can lead space exploration with minimal capital. In this episode of DIB Innovators, Bradley shares with Dave how his 14-year journey began with a purpose to enable the sustainable exploration, development, and settlement of space. 
 
Rather than building hardware, his team focused on creating technologies, capabilities, software, and mission design solutions that didn't require giant rocket factories or satellite production facilities. This approach led to operating the CAPSTONE mission (Cislunar Autonomous Positioning System Technology Operations and Navigation experiment): a microwave-sized satellite that's been orbiting the moon for over two years in a novel orbit never used before, pathfinding NASA's Artemis program for under $30 million without outside investment.
 
Topics discussed:
 
The counterintuitive approach of focusing on enabling technologies instead of hardware manufacturing, allowing Advanced Space to grow from 12 to 100 people and reach the moon without venture capital by reinvesting customer revenue into strategic capability development.
How Advanced Space's focus on advanced astrodynamics reduced mission costs by 75%, transforming what would have been a $120M+ traditional mission into a sub-$30M pathfinder by designing transfer orbits that accommodate smaller spacecraft with less fuel.
How the Cislunar Autonomous Positioning System (CAPS) solves the Deep Space Network's bandwidth limitations by establishing satellite-to-satellite communication, successfully demonstrated by linking with the decade-old Lunar Reconnaissance Orbiter that was never designed for such interaction.
Why this unprecedented orbit solves multiple lunar mission challenges simultaneously, providing constant Earth visibility, minimizing solar eclipses to prevent spacecraft freezing, enabling access to any point on the lunar surface, and facilitating efficient Earth-Moon transfers.
How Advanced Space recovered from two near-mission-ending anomalies by leveraging NASA partnerships and attempting never-before-tried techniques, including successfully freezing and thawing propellant in space when conventional recovery methods failed.
Advanced Space's years-long development of machine learning and neural networks for satellite operations, moving beyond theoretical applications to successfully demonstrating these technologies in lunar orbit two years before the current AI boom.
Why the future of lunar exploration depends less on individual mission capabilities and more on developing autonomous operations, communications networks, and navigation systems that can overcome Earth-based infrastructure limitations as mission frequency increases.

EP 57 — Cyber Resilience at the Crossroads [Webinar]

The security landscape has radically transformed from counter-terrorism to strategic competition with nation states who are actively positioning cyber assets to disable American infrastructure during potential conflicts. In this vital discussion examining National Security Memorandum 22 (NSM-22), Gen. VanHerck, former Commander of United States Northern Command and North American Aerospace Defense Command, shares that 80% of force projection in any global crisis flows from homeland facilities dependent on civilian infrastructure — from local energy grids to transportation networks, creating an unprecedented vulnerability that adversaries are exploiting daily. 
 
Kevin Phillips, Chairman of the Board of ManTech, provides a rare insider perspective on how nation states have spent decades mapping defense industrial base networks, explaining that it's safe to assume that no matter what size you are, you're on somebody's radar and detailing his 10-year journey implementing zero trust architecture to counter these threats. 
 
Mark Montgomery, Sr. Director & Sr. Fellow at Foundation for Defense of Democracies, delivers the most alarming assessment: China's Volt Typhoon campaign has already embedded malware throughout rail, aviation, ports, and power grids as operational preparation of the battlefield. All this and more on this special episode of DIB Innovators! 
 
Topics discussed:
 
The transition from cyber espionage to operational battlefield preparation by nation-state actors targeting the 80% of military deployment capabilities that rely on civilian infrastructure, creating a dual vulnerability where domestic critical systems become frontline targets.
Implementing a decade-long zero trust architecture strategy that systematically eliminates technical debt, narrows network footprints, and implements micro-segmentation before attempting advanced security measures—a methodology proven successful at Mantech.
Why China's Volt Typhoon operation represents a fundamental shift in cyber warfare tactics, embedding dormant capabilities throughout transportation, energy and communications networks as part of a deliberate 25-year strategy following the 1995-96 Taiwan Strait crisis.
The critical flaw in NSM-22's approach to critical infrastructure protection through its failure to establish mandatory prioritization criteria for the approximately 500 most vital national assets, while simultaneously dismantling effective public-private collaboration frameworks.
How living off the land attack techniques have evolved to mimic legitimate network traffic patterns, requiring organizations to make network penetration prohibitively expensive through comprehensive identity management and application control rather than relying on detection.
The operational reality that SMBs face existential threats from cyber incidents with only 4-8 weeks of financial float while remediation typically requires 3-4 weeks, exemplified by the $4 billion emergency Medicare advance during the Change Healthcare attack that still resulted in $1 billion taxpayer losses.
The strategic use of cloud services and infrastructure-as-a-service models to maintain current patching and upgrades when internal operations lack capacity, creating resilience against nation-state threats that specifically target update delays and technical vulnerabilities.
Addressing the asymmetric security gap where government would respond to physical attacks on critical infrastructure but companies are left to defend themselves against sophisticated cyber attacks from the same actors, potentially requiring National Guard cyber response teams instead of relying solely on CISA hurt teams.
Brought to you by RADICL — Cybersecurity-as-a-Service purpose-built for small and mid-sized businesses in the Defense Industrial Base. Starting your CMMC journey? RADICL guides and accelerates your compliance—while reducing ransomware and other cyber risks—with a transparent, turn-key solution.
radicl.com/cmmc_solved

EP 56 — SkyRunner’s Stewart Hamel on How Their Unmanned, Multi-Domain Aircraft Enhances Strategic Capabilities for Special Ops

Stewart Hamel, CEO, took an eccentric side project for his ranch and transformed it into SkyRunner, a revolutionary air utility transport vehicle that's changing the future of defense sector mobility. In this episode of DIB Innovators, Stewart tells Dave how a viral CNN Money video caught military attention, leading to design input from special operations teams that transformed his vehicle into a tactical platform with dual-engine redundancy, field-serviceable components, and the ability to operate even after taking direct fire. 
 
With a deployment speed of seven minutes versus a Blackhawk's 30 minutes and a price point 1% of traditional aerial systems, SkyRunner can run missions like deliver medical supplies faster than helicopters in 10-mile scenarios while providing ground and air domain flexibility that traditional aircraft can't match. Now with 130+ vehicles in production for four countries and growing interest in unmanned capabilities for GPS-denied environments, Stewart shares his insights on navigating defense partnerships and preparing for acquisition in order to be of even greater impact.
 
Topics discussed:
How a recreational flying vehicle project intended for family use evolved into a tactical solution after a CNN interview resulted in calls from SEAL Team 6 looking to solve specific operational mobility challenges.
SkyRunner's space shuttle-inspired redundancy engineering ensures continued operation even after catastrophic damage — including maintaining mobility with a damaged engine block, lost coolant, or compromised axles.
SkyRunner's intuitive control system allows operators to become certified pilots in just two weeks versus 8-9 months for traditional aircraft, reducing the training barrier for tactical aviation.
All critical components use cannon plug connections and interchangeable parts, enabling quick repairs without specialized training and addressing a critical need for forward deployment scenarios.
The dual-engine system enables 70 mph ground speed with wheels and 85+ mph using just the propeller system if ground components are compromised, providing multiple mobility options in contested areas.
SkyRunner's adaptation to autonomous operation specifically designed to function in GPS-denied and jammed environments, addressing vulnerabilities exposed in Ukraine and other contested domains.
How demonstrating at the Fort Lauderdale Boat Show rather than traditional defense expos provided market validation and an alternative path to military adoption.
Building relationships with major defense contractors like Collins Aerospace, Raytheon, and AeroVironment to integrate existing military systems rather than competing, creating win-win scenarios.
Brought to you by RADICL — Cybersecurity-as-a-Service purpose-built for small and mid-sized businesses in the Defense Industrial Base. Starting your CMMC journey? RADICL guides and accelerates your compliance—while reducing ransomware and other cyber risks—with a transparent, turn-key solution.
radicl.com/cmmc_solved

EP 55 — Piasecki Aircraft’s John Piasecki on Their Answer to Extended-Range Combat Logistics

Vertical lift aviation is on the cusp of its biggest revolution since the helicopter itself, and John Piasecki, President & CEO of Piasecki Aircraft, is at the forefront with game-changing technologies that could cut operational costs in half while meeting complex military requirements. 
 
In this episode of DIB Innovators John walks Dave through how his family's aerospace legacy is evolving from the iconic tandem rotor helicopter (now the Chinook) to hydrogen-powered compound helicopters and tilt-duct VTOL platforms. 
 
The discussion illuminates the strategic shift from pure R&D to production capability with their acquisition of Sikorsky's Heliplex facility, while exploring how their innovations directly address the challenges of Ukraine's contested airspace and the vast distances of Indo-Pacific operations.
 
Topics discussed:
 
How Ukraine's battlefield realities have driven an "asymptotic" increase in air defense lethality, forcing a shift toward unmanned vertical lift systems for logistics in contested environments.
The strategic advantages of high-temperature proton exchange membrane fuel cells that deliver 5x the energy density of batteries and require significantly fewer maintenance-intensive components than turbine engines.
Why hydrogen fuel propulsion could reduce vertical lift operational costs by 50% compared to conventional turbine helicopters while enabling units to generate their own fuel with just water and energy.
How the Ares tilt-duct VTOL platform solves the critical gap between V22 Osprey capabilities (300+ mile range) and conventional helicopter support that can't match this extended operational radius.
The potential for additive manufacturing to transform dynamic component production, reducing 12+ month lead times for critical parts like gearbox castings and cutting development cycles significantly.
How software-enabled "cyber rotorcraft" technology could extract 15-20% more capability from identical hardware by replacing traditional safety margins with real-time adaptive flight control systems.
The challenges of transitioning from SBIR program success to production at scale, prompting Piasecki's acquisition of Sikorsky's Heliplex facility after 60+ years as a pure R&D company.
The shift toward mission-manager operators instead of traditional pilots, potentially solving the commercial and military pilot shortage while broadening access to vertical lift mobility.

EP 54 — Slingshot Aerospace’s Erik Ekwurzel on Low-Cost Optical Alternatives for Space Radar Systems

In Dave’s latest conversation on DIB Innovators, he uncovers how Slingshot Aerospace has become one of the few major entities globally collecting space data at scale, alongside superpowers like the US, China, and Russia. Erik Ekwurzel, CDIO, explains how their patented optical sensor technology, which is deployed across 22 global sites, can detect objects as small as CubeSats while collecting critical photometric data that radar systems can't capture. 
 
As space becomes increasingly contested and congested, and with satellite numbers projected to grow from 12,000 today to potentially 100,000 in less than a decade, Slingshot's mission to deliver "decision-valued data" for safe space operations has become crucial for both government and commercial operators. 
 
Topics discussed:
 
How Slingshot's physics-true AI training environment gives them an edge in space domain awareness, allowing their AI to immediately focus on patterns rather than wasting time learning basic physics principles.
How Slingshot's global network of optical sensors generates over 1 billion space observations every six months (8-10 million daily), making them a major global entity collecting space data at scale.
The competitive advantage of using staring arrays versus traditional cueable sensors, including the ability to monitor large sections of space simultaneously without needing to be repositioned, which allows them to detect both known and previously unidentified objects.
How Slingshot applied AI to develop GPS jamming and spoofing detection capabilities for the US Space Force, identifying ground-based interference with satellite signals.
The significant cost efficiency of Slingshot's optical sensor approach: sub-million dollar deployable systems versus traditional radar installations that require football-field-sized infrastructure and massive power supplies.
The exponential challenges of space traffic management as orbital congestion increases, illustrating why AI-assisted decisions will soon become essential for satellite operators facing ever more risks.
The tension between intellectual property rights and government procurement in the DIB, with agencies often wanting to purchase rather than license proprietary technology, creating sustainability challenges for innovative companies.
The critical need for real-time data processing at scale, with Slingshot working to minimize latency from sensor observations to actionable intelligence while maintaining 99.999% system uptime.