Episode 22 - Lights Out, Bots On with Graham Francis

  • 109 min

#22 Lights Out, Bots On with Graham Francis

Chips and Tips Podcast

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In this episode of Chips and Tips, Justin from Toolpath sits down with Graham Francis of Lights Out Manufacturing to talk about the real-world side of machine automation. From the trade-offs between pallet and part loading to the nuts and bolts of integrating a cobot with your CNC, this conversation cuts through the marketing noise to reveal what automation really takes. Graham shares lessons learned from building and running robotic systems that work reliably—day and night—and what it means for shops ready to take the leap.

Lights Out, Bots On with Graham Francis episode summary

When most machinists think about automation, they picture a complex, high-cost setup reserved for big factories. But as Graham Francis of Lights Out Manufacturing explains, the real story of CNC automation is simpler, more approachable, and already within reach for most shops. In this conversation with Justin from Toolpath, Graham unpacks the evolution of his company from custom robotics to turnkey cobot systems that let small and mid-size shops run truly lights out.

At the core of the discussion is the difference between pallet loading and part loading. Graham makes a compelling case that while pallet systems can make your work more efficient, only part loading actually reduces the amount of manual labor. He and Justin explore how real-world automation decisions are about trade-offs—floor space, rigidity, and accuracy—rather than hype. The insight is clear: automation succeeds not when it looks futuristic, but when it makes your existing processes simpler and more consistent.

The pair also dive into what it really takes to install a cobot. From epoxy floor plates and pneumatic vices to smart sensing moves that mimic human touch, Graham’s team has thought through every detail to make robots as easy to live with as any other machine in the shop. His stories from IMTS—where their cobot ran 25 different setups amid the chaos of a trade show—show that reliability isn’t theoretical. It’s earned, iteration by iteration.

A standout moment comes when Graham explains why “cobot” is a misunderstood term. What sets them apart isn’t the friendliness—it’s the force-torque sensing that lets the robot “feel” its way into workholding just like a human operator would. It’s this sensitivity, he argues, that makes automation viable even for small-batch, high-mix manufacturing.

The conversation closes with a grounded view of automation as a journey, not a switch. Whether it’s debating cobots versus industrial robots, designing self-aligning soft jaws, or learning when to call in a robot integrator, the takeaway is empowering: modern automation isn’t about replacing machinists—it’s about multiplying what they can do. For any shop owner still on the fence, this episode proves that practical, lights-out manufacturing is already here.

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