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The Merge

The Merge
The Merge
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67 episodes

  • The Merge

    E62 – Rethinking Aircraft Maintenance with Perfect Point EDM

    2026/10/04 | 27 mins.
    Buying a fighter jet is the cheap part.
    Mike sits down with Jim Becker, President and CEO of Perfect Point EDM, to talk about the biggest line in any defense program: keeping the fleet flying.
    Perfect Point builds the E-Drill, which uses electro discharge machining (EDM) to pull aircraft fasteners. Founded in 2005, it turned a lab curiosity into a fielded tool that removes a rivet in about 30 seconds instead of 10 minutes, with no debris and almost no rework.
    Jim's take is blunt. The aircraft modernized, the maintenance tooling did not, and the industry keeps papering over it by leaning on a shrinking pool of skilled mechanics.
    Topics include:
    Operations and maintenance as the biggest cost in a program

    Electro discharge machining applied to fastener removal

    Cutting a 10 minute rivet job down to 30 seconds

    Eliminating foreign object debris and rework on titanium airframes

    Why maintenance tooling never modernized

    Winning over risk-averse engineers with the material science case

    The shrinking pool of skilled aircraft mechanics

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    Links
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    Perfect Point EDM homepage https://www.ppedm.com/

    Perfect Point EDM LinkedIn https://www.linkedin.com/company/perfect-point-edm/

    Jim LinkedIn https://www.linkedin.com/in/jim-becker-48449790/

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    Chapters
    00:00
    00:28 intro
    02:06 the MRO space
    02:53 the founding story
    04:38 from the Marine Corps to Boeing
    06:10 framing the rivet problem
    07:01 tooling stuck in the 60s
    07:43 titanium and steel fasteners
    08:54 no FOD, no mess
    09:46 the three step process
    10:27 four to five times faster
    10:49 killing the rework
    11:52 problems everybody just accepts
    13:49 the miracle-worker culture
    14:55 the aging workforce
    16:49 winning over the engineers
    17:32 the launch that fell flat
    20:21 SBIRs and the valley of death
    21:39 fall in love with the problem
    22:09 conventional wisdom that's wrong
    24:47 making do with less
    26:03 go talk to the mechanics
    28:29 the stance he'll defend
    30:12 where to learn more
    31:03 outro
  • The Merge

    E61 – Rebuilding the Test Playbook with Nominal

    2026/08/30 | 36 mins.
    Test is where new military hardware goes to wait.
    Mike sits down with Jenn Wilson, Head of Federal at Nominal, to talk about test and evaluation, the least glamorous gate between a program and the warfighter.
    Nominal builds test data infrastructure for hardware. Founded in 2022 by Anduril, Palantir, and Lockheed Martin alumni, it reached a $1 billion valuation in March.
    Jenn’s take is that acceleration comes from optimizing what you test for. Cutting test points is the wrong lever.
    Topics include:
    Test and evaluation as a mission enabler

    High rate, multimodal test data

    Real-time telemetry and closing the test loop

    DARPA CIPHER Forge and digital twins

    Closing the sim to real gap

    The F-35 crowdsourced flight data program

    Knowledge parity between primes and government testers

    Links
    Sign up for the newsletter! https://www.themerge.co/

    Support us on Patreon! https://www.patreon.com/the_merge

    Nominal homepage https://nominal.io/

    Nominal careers https://nominal.io/careers

    Nominal LinkedIn https://www.linkedin.com/company/nominal-inc/

    Jenn LinkedIn https://www.linkedin.com/in/jennifer-t-wilson

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    Instagram https://www.instagram.com/merge_newsletter/

    X https://x.com/MergeNewsletter

    Facebook https://www.facebook.com/themergenews

    Website https://www.themerge.co/

    Chapters: 
    00:00
    00:32 intro
    01:47 why this, why now
    02:32 test is not sexy
    03:47 test as an afterthought
    05:40 more data, less insight
    07:18 where the name comes from
    07:54 the founding story
    10:43 Mike is a user
    11:16 streaming telemetry in real time
    13:14 design of experiments
    15:17 the Fid Labs acquisition
    16:31 DARPA CIPHER Forge
    19:35 closing the sim to real gap
    20:21 the commercial side
    23:31 lessons from Ukraine
    25:00 F-35 crowdsourced flight data
    27:15 fleet bugs found in days
    29:07 combined test force
    31:50 experimental operations unit
    32:34 speeding up test
    33:09 the pilot taking fire
    34:21 knowledge parity with the primes
    35:18 a billion dollar valuation
    36:03 hiring at Nominal
    #defensetech #podcast #military #testandevaluation #flighttest #digitaltwins #darpa #f35 #autonomy #nationalsecurity #airforce #dualuse #militarytechnology
  • The Merge

    E60 – GPS-Free Navigation

    2026/07/12 | 43 mins.
    How do systems operate when GPS disappears?
    Mike sits down with Kara Kramer, Vice President ofRaptor Sales at Vantor (formerly Maxar Intelligence), to discuss one of the most important challenges facing modern autonomous systems: operating when GPS is jammed, spoofed, or completely unavailable.

    We discuss vision-based navigation (VBN), 3D geospatialintelligence, and why resilient autonomy depends on more than just the drone itself. From electronic warfare to contested operations, this conversation examines how software and spatial intelligence are enabling unmanned operations, and Vantor’s unique approach.
    This isn’t just about navigation—coordinate generation and targeting elements are equally important.
    Topics include:
    • Vision-based navigation
    • 3D geospatial intelligence
    • Targeting without GPS

    BONUS: Kara also shares her professional journey and how she got into the defense industry!

    Whether you're building autonomous systems, working indefense technology, or simply interested in where drone technology is headed, this episode provides an inside look at one of the fastest-moving areas in aerospace.
    TOGETHER WITH VANTOR.

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    Links
    • Sign up for the newsletter⁠!
    • Support us on ⁠Patreon⁠!
    • Vantor home page
    • Vantor Raptor product page
    • Raptor inquiries
    • Vantor on LinkedIn   
    • Kara Kramer on LinkedIn   
     
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    ----
    00:00
    00:01:11 intro
    00:01:54 Vantor history
    00:03:26 Raptor origins
    00:03:59 Vantor backstory
    00:05:39 The SpaceX of VBN
    00:06:32 Raptor VBN
    00:10:11 issues with GPS
    00:12:44 pre-GPS terrain nav
    00:13:46 the Hub
    00:15:20 no hardware?
    00:17:57 how it all works
    00:20:47 geo-registered coordinates
    00:26:27 Kara's journey in defense
    00:28:24 Vantor in Drone Dominance
    00:35:19 Vantor partnerships
    00:39:02 contrarian takes
    00:40:37 fast cheap good triangle
    00:42:01 final thoughts
     
    #defensetech #dronetechnology #autonomy #gps #jamming #electronicwarfare #uas #drones #militarytechnology #geospatial #navigation #navigation #pnt #isr #aerospace #defenseinnovation #nationalsecurity #intelligence #intel #military
  • The Merge

    E59 – Business Breakdown: Anduril

    2026/06/04 | 42 mins.
    Anduril Industries raised $5 billion at a reported $61billion valuation—putting a nine-year-old defense tech company in the same conversation as legacy primes that have been building weapons for generations.

    How did they do it, what is their strategy, and does the math make sense?

    In this episode, Mike and Matthew take a deep dive inside Anduril’s products, revenue, contracts, and business strategy. They break down the Series H raise, the company’s rapid valuation climb, the difference between contract ceilings and booked revenue, and why visible federal obligations onlytell part of the story.

    They also examine Anduril’s expanding product portfolio, anddebate the core question behind the company’s $61B price tag: Is Anduril the future of defense industrial production, or is the market pricing in near-flawless execution?

    Topics include:
    - Anduril’s $5B Series H and $61B valuation
    - The gap between reported revenue and visible federalobligations
    - Why Special Operations and the Border Patrol matter morethan most people realize
    - The $20B Army enterprise vehicle—and why it is a rail, not acheck
    - Barracuda, Fury, Arsenal-1, and hyperscale defensemanufacturing
    - How Anduril compares to Lockheed, Northrop, GeneralDynamics, RTX, and Palantir
    - The bull and bear case for Anduril’s long-term strategy
    - What to watch next: IPO timing, task orders, deliveries, andrevenue growth
    - The real bet: for Anduril to justify today’s valuation, ithas to grow from a $2B revenue company into a $20B+ revenue company very quickly.

    SUBSCRIBE FOR FREE to get more intel on defense tech, news, and happenings.
     
    Links
    • Sign up for the newsletter⁠!
    • Support us on ⁠Patreon⁠!
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    • ⁠X⁠
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    ----
    00:00
    00:34 intro
    01:20 Premium newsletter!
    02:10 Anduril intro
    02:26 Matthrew intro
    04:32 Anduril 101
    06:52 Anduril's fundraising
    07:25 the next 24 months
    07:38 revenue breakdown
    08:23 happenings between the raises
    14:10 last 5 years of sales
    15:47 counter-UAS
    18:22 Steve vs Steve approach
    19:14 C-UAS durability?
    21:04 Altius
    21:52 comparing valuations
    23:21 sources of new revenue
    23:33 Barracuda
    24:08 CCA program
    27:28 Lattice
    28:20 Eagle Eye
    31:18 Golden Dome
    35:08 Anduril's strategy
    38:53 next acquisition?
    41:25 wrap-up
  • The Merge

    E58 – Dcode the Pentagon Buying Machine

    2026/04/26 | 51 mins.
    What does it actually take to get new technology into thehands of warfighters—and why is it still so hard?
    In this episode, Mike sits down with the co-founders ofDcode, Meagan Metzger and Meg Vorland, to unpack the reality behind defense innovation, acquisition reform, and the flow of capital into the sector.
    Dcode operates at a unique intersection—working withstartups, investors, and the Pentagon—giving them a rare, inside-out view of how the system really works.
    We break down why most acquisition reform efforts fallshort, whether recent policy changes are hitting the right targets, and what conventional wisdom in defense innovation is simply wrong.
    If you’re trying to understand how defense actually getsbuilt, funded, and fielded—this is the inside baseball.

    Links
    • Sign up for the newsletter⁠!
    • Support us on ⁠Patreon⁠!
    • Dcode website
    • Dcode Capital portfolio
    • Dcode LinkedIn
    • Meagan Metzger LinkedIn
    • Meg Vorland LinkedIn
    • CTRL + ALT + DEFENSE podcast

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    Follow us on...
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    ----
     
    00:00
    00:44 intro
    01:19 Dcode origin story
    04:55 founders, funders, and fighters
    09:27 acquisition reform
    12:32 risk vs the no-monster
    15:58 buying speed vs rigor
    16:44 contracting officer shortage
    17:55 bigger worse contracts
    21:04 defense catalyst
    21:57 leadership and training
    23:05 the bigger picture
    25:33 budget line-item consolidation
    28:16 pass a budget
    30:41 investing in companies
    36:05 misconceptions
    38:28 colors and fallout
    39:33 conflicts of interest
    41:03 RAIC
    41:30 300
    42:12 pilot programs
    46:42 fielding
    47:29 magic wand
    48:49 crystal ball
    50:19 outro
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About The Merge
Military technology, trends, and national security...presented with unique insights, salt, and wit from combat aviator veterans and industry experts. Fence in for interviews and anecdotes about the ins, outs, and happenings at the intersection of technology, industry, strategy, and policy of aerospace and national defense. Brought to you by The Merge newsletter.
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