Within the College of Engineering, the machine shops stand as the cornerstone of Cal Poly’s celebrated hands-on learning approach.
These dynamic hubs of creativity and innovation are where theoretical knowledge meets practical application, enabling students to undertake projects that are not just assignments but the foundation of their education.
Yet, the operation of these facilities hinges on the dedication and skill of the student shop technicians, who are as much a part of the machinery as the lathes and milling machines they run.
“The shops simply couldn’t function without the techs,” said shop manager Eric Pulse, who has been on the job for 16 years. “We’re unique in this approach – no other school operates quite like we do.”
Students from nearly 100 majors flock to the Mustang ’60 and Hangar machine shops, using every available hour and inch of space. Their projects are as diverse as their disciplines, spanning from constructing race cars to creating prosthetics for senior projects.
Despite the wide range of their projects, one common thread binds all these students together: the requirement to be trained by a shop technician before they can access either facility.
Soaring demand
Student shop technicians annually provide safety training to nearly 2,000 students, teaching proper machine operation and safety. Most training happens in the fall of freshman year, coinciding with classes that require shop certification.
Once certified with red tag clearance, students can access the shops, always under the supervision of shop techs who ensure safety.
Pulse manages a record number of 76 shop techs to accommodate the high demand for shop access.
Among the equipment, CNC machines, lathes, mills and routers are favored by students for various projects. However, 3D printers are particularly notable for their ability to quickly produce intricate designs.
Alan Onuma, shop tech and 3D printing supervisor, began monitoring printer usage this year, revealing remarkable statistics that underscore the extensive use of the printers.
During the winter quarter alone, students used 25 miles of filament across 9,943 hours, amounting to about 414 days of nonstop printing. Since their introduction to the shops around 18 months ago, the total usage has soared to 99 miles of filament over 40,500 hours, equivalent to 1,688 days.
Reflecting on the data, Onuma – drawn to Cal Poly’s mechanical engineering program for its student-operated, accessible machine shops – expressed his astonishment: “I knew the printers were heavily used, but these numbers are truly mind-boggling.”
In his role, Onuma not only educates other shop techs on the printers but also repairs them, having fixed the 16 printers 80 times just last quarter.
He became proficient in printer repairs eight years after buying his own and further developed his expertise through internships. He is looking forward to enhancing his skills at Boeing’s 3D printing prototyping lab near Seattle this summer.
As he approaches his final quarter as a shop tech, Onuma is enthusiastic about witnessing the completion of senior and club projects and preparing his successor in 3D printing supervision.
“I love seeing the incredible projects come to life,” he said.
One of Onuma’s highlights has been introducing new students to the shop, often starting with the 3D printers, which provide an easy entry point for beginners.
“The printers are like a gateway drug,” Onuma said with a laugh. “Once students start creating, many are inspired to explore and use the other equipment in our shops.”
Safety first
Annually, about $180,000 from state and discretionary funds is dedicated to equipment and improvements within the machine shops. However, funding for the shop tech program comes from donors and industry partners.
Growing the shop tech fund will be a central focus for the College of Engineering during Poly Gives – a three-day digital fundraising event aligning with Open House weekend from April 11 to 13.
“Anyone engaged with the system quickly recognizes the critical role of shop techs,” Pulse said. “Those in the know truly understand their value.”
Their primary importance stems from ensuring the safety of student users.
This year, Pulse has taken on the role of vice president for the nationwide Student Shop Managers Consortium, a body dedicated to hosting the leading conference on the safe operation and development of academic shops.
The consortium, established in 2015, was the brainchild of Duke University’s shop manager, motivated by a heartrending event in which a 22-year-old Yale student was fatally injured in a machine shop. Her hair got caught in a fast-spinning lathe while she was working on her senior project, prompting a call to action for enhanced safety measures.
Pulse, a founding member of the consortium, has played a pivotal role in its evolution, highlighting Cal Poly’s unique student-operated shops in his presentations to members.
In 2026, Cal Poly is set to host the conference, attracting 120 shop managers, assistants and directors from across the nation.
“My primary focus over the next two years is to prepare for hosting the event and showcasing our state-of-the-art shops that truly inspire awe,” he said.
He will also continue to mentor the student shop techs, whose efforts have secured an exemplary safety record for Cal Poly’s machine shops.
“The students take great ownership and pride in our shops,” he said. “To them, the shops are as vital as they are to me.”
To support the shop tech program during Poly Gives, visit here.
By Emily Slater
