Simultaneous 5-axis machining of complex aerospace geometry. Titanium (Ti-6Al-4V, Ti-CP), Inconel 625/718, hardened tool steels, aluminum 7075/AL-Li.

TOLERANCE

±0.0002"

ENVELOPE

30 × 24 × 22"

SPINDLE

20K RPM · HSK63

MACHINES

DMG-MORI · HAAS · MAZAK

Swiss-type and multi-axis mill-turn cells for high-aspect-ratio, high-tolerance rotational components.

BAR DIA

0.04" – 4.0"

LENGTH

UP TO 36"

LIVE TOOLING

Y-AXIS + C-AXIS

MACHINES

DOOSAN · TSUGAMI

Metal DMLS / SLM, plastic SLA, MJF, and FDM. From CAD to functional prototype within 72 hours for qualifying programs.

DMLS MATL

INCONEL · TI · 17-4 PH

LEAD TIME

72H STANDARD

LAYER RES

20 µm

BUILD VOL

250 × 250 × 325 mm

Validated, repeatable serial production. PPAP, FAIR, and SPC integrated into the Forge OS. Lot sizes from 100 to 100,000.

LOT SIZE

100 – 100K

CAPACITY

24 / 7 LIGHTS-OUT

YIELD

99.4% AVG

TRACKING

FORGE OS · MISSION

Design for manufacturability, tolerance stack analysis, fixture and tooling design, process engineering, and program management.

DFM REVIEW

INCLUDED

TOL ANALYSIS

GD&T · ASME Y14.5

CAD

SOLIDWORKS · NX · CATIA

CAM

MASTERCAM · HYPERMILL

AS9100, CMMC L2, ITAR registered. CMM, laser scanning, surface profilometry, and full traceability with material certs and FAI per AS9102.

CMM

ZEISS · 0.5 µm

FAI

AS9102 REV C

CERTS

AS9100 · CMMC · ITAR

TRACE

HEAT-LOT TO PART

Mechanical and electromechanical sub-assembly, kitting, torque-controlled fastening, and packaged delivery.

CLEAN ROOM

ISO CLASS 8

TORQUE

CALIBRATED · LOGGED

KITTING

BARCODED

PACK

MIL-STD-2073

When processes are out-of-house — anodize, plating, heat treat, EDM, NDT — the Forge routes work to vetted vendors with full chain-of-custody.

NETWORK

40+ VETTED

PROCESS

ANODIZE · PLATE · HT

NDT

FPI · UT · RT

TRACE

END-TO-END

Dedicated program managers, mission-based tracking, milestone reporting, and executive briefings for every program.

PM RATIO

1 : 4 PROGRAMS

REPORTING

WEEKLY · IPMR

TOOLS

FORGE OS

ESCALATION

<2H