Programs we've executed.
A selection of programs across counter-UAS, hypersonics, space, and robotics. Customer names redacted for ITAR and competitive reasons.
Counter-UAS gimbal housing — 0 to FAI in 18 days
CHALLENGEA venture-backed C-UAS prime needed a flight-qualified 5-axis gimbal housing from a single CAD model with zero existing tooling.
SOLUTIONForge engineering ran DFM in 4 hours, qualified Ti-6Al-4V supply, machined first article on a DMG-MORI NTX-2500, and delivered AS9102 FAI documentation.
RESULT18d proto-to-FAI · 100% first-pass yield · production lot awarded.
Inconel 718 thrust collar — production-ready process
CHALLENGEA hypersonics startup needed a thrust collar that historically required hand-finishing to meet TIR specs.
SOLUTIONForge developed a fixture + process combining HSM roughing with in-process probing, eliminating manual finishing entirely.
RESULTTIR held at ±0.0001" across 240 units · 41% cycle time reduction.
Cubesat structural ribs — AL-Li lightweighting program
CHALLENGEA satellite manufacturer needed to reduce structural mass without sacrificing stiffness on a 12U cubesat.
SOLUTIONForge engineering proposed AL-Li 2099 with a topology-optimized rib geometry; verified via CMM and modal testing.
RESULT37% mass reduction · stiffness within 4% of baseline · flight qualified.
Field-robotic harmonic-drive housings — at scale
CHALLENGEA defense robotics prime needed 4,200 harmonic-drive housings in 90 days with tight concentricity.
SOLUTIONForge scheduled a dedicated mill-turn cell with lights-out night shifts and integrated SPC into the Forge OS.
RESULT4,200 units delivered in 76 days · 99.7% first-pass yield.