What would you do if your very first CNC machine didn't even power on? For most people, that's where the story would end. But for Rhys Andersen, it was just the beginning.
In this episode, I sit down with one of the most determined shop owners I've ever interviewed. Rhys is the founder of Method Manufacturing in Austin, Texas — and his journey into precision machining is anything but conventional. From wildland firefighting to architecture school to a series of trial-by-fire business ventures, Rhys took the long road to building a thriving aerospace and defense machine shop.
You'll hear how he bootstrapped his first massive bed mill (without even knowing if it worked), taught himself CNC machining, and slowly transformed a one-machine operation into a fully cross-trained, process-driven company with advanced 5-axis automation.
We dig into how relationships opened doors to major aerospace work, the real challenges of hiring and developing talent, and how Method's unique approach to systems and autonomy allows his team to perform at a high level — without sacrificing their personal lives.
This conversation is full of practical lessons for any shop owner trying to scale, build processes that actually work, and free themselves from being the "best machinist in the shop." Rhys's story is proof that grit, humility, and systems thinking can take you further than raw skill alone.
You will want to hear this episode if you are interested in...
- (0:20) Stay tuned for Top Shops 2025 registration!
- (2:57) Rhys's background: growing up in fabrication and firefighting
- (5:19) The first business failure and how it led to starting Method
- (9:06) Learning how to machine and going full-time after losing his oilfield job
- (11:27) The mindset of perseverance and problem solving
- (12:37) Buying a machine that was stored in a barn (and fixing it up)
- (15:12) What Rhy's business looks like present day
- (17:17) Breaking into aerospace: Patience, persistence, and building trust
- (23:16) Lessons learned from hiring mistakes and building a strong team
- (27:40) Achieve on-time delivery with ProShop ERP
- (28:53) Creating a culture of extreme autonomy and flexible schedules
- (31:21) Cross-training machinists and eliminating single points of failure
- (34:14) Using Fulcrum to capture tribal knowledge and improve processes
- (36:58) Changing the perception of machining as a high-tech, creative career
- (41:07) Why shop owners need to get out of the shop and network
- (45:14) The challenge of scaling: building systems that don't rely on you
- (47:25) Investing in automation to enable growth and better work-life balance
- (50:47) Why investing in branding, photos, and professional image matters
- (54:30) Bringing anodizing in-house to control quality and reduce headaches
- (56:34) What is your entry into the market?
- (58:35) Why you need to Listen to the Lights Out podcast
Resources & People Mentioned
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