D-0 // Requirements Document
A napkin sketch. A napkin sketch with tolerances. Your program's next gate review is in 3 weeks.
D+14 // Flight-Ready Prototype
Machined titanium. Dimensional report attached. Ready for your gate review.
From requirements document
to your hands.
Faster than your procurement cycle. Forge runs 6-axis CNC mills through the night cutting titanium while engineers iterate CAD models in the next room. SBIR Phase II, DOD demonstrators, dual-use autonomy hardware — we close the gap between concept and flight-ready metal.
Capability Matrix
Six core competencies. Every card leads with the number a program manager needs before they read the paragraph.
Titanium. Inconel. 7075 Alloy.
UAV Structural Frame
Titanium airframe bracket for small UAS — 14 unique parts, full dimensional report, delivered to prime contractor in 11 days from approved drawing.
DMLS / SLM In-House.
Thermal Management Housing
Complex internal lattice cooling channels impossible to machine — printed in Inconel 625, HIP processed, pressure tested to 3× operating load.
MIL-STD-810H In-House.
EO/IR Gimbal Assembly
Full MIL-STD-810H Methods 514.8, 516.8, and 501.7 on a gimbaled EO/IR payload — test report delivered same day as completion, gate review cleared.
Scan-to-CAD in 48 hrs.
Obsolete Actuator Housing
No drawing, no digital model — 1970s-era actuator housing for a legacy system. Scanned, modeled, tolerance-verified, and reproduced in aluminum in 6 days.
Embedded Systems. Flight Computers.
Dual-Use Nav Computer
Custom flight computer for a dual-use autonomous platform — sensor fusion board, ruggedized enclosure, and full functional test in under 3 weeks from schematic.
Hardware-in-the-Loop Ready.
Hypersonic Seeker Demo
Full seeker demonstrator — optics, gimbals, electronics, and enclosure — integrated and HIL-tested against government-provided simulation environment in 21 days.
Past Performance
Classification-safe summaries. Every entry is a number, then a proof — the evidence wall a program manager needs before they can justify sole-source.
SBIR Phase II — Air Vehicle Structures
Mid-tier defense prime, Southwest division
Deliverable
Titanium airframe subassembly, 23 unique parts, full AS9100D documentation package
Outcome
Delivered 4 days ahead of SBIR milestone gate. Prime used prototype for Phase III proposal imagery.
DOD Acquisition Demonstrator — Unmanned Ground Vehicle
Program Executive Office, Ground Combat Systems
Deliverable
Aluminum structural chassis with embedded sensor mounts, environmental sealed to IP67
Outcome
Demonstrator operated at Aberdeen Proving Ground during acquisition gate review. Contract awarded.
Dual-Use Autonomy — Navigation Hardware
Series-B funded autonomy startup, commercial + defense dual-use
Deliverable
Custom navigation computer enclosure, PCB integration, full thermal analysis, vibration tested to MIL-STD-810H
Outcome
Hardware shipped to customer within 19 days of signed NDA. Startup used prototype to close $12M defense contract.
Legacy System Sustainment — Obsolete Actuator
Depot-level maintenance organization, CONUS
Deliverable
Reverse engineered actuator housing, no drawing available, reproduced to original spec from scan data
Outcome
Part matched OEM dimensions within 0.0004″. 40-unit production run followed within 30 days.
Full past performance package available upon request with .mil or .gov email verification
Facility & Credentials
The compliance stack a program manager needs to justify sole-source. Every certification earned, not claimed.
Key Equipment
Partial ListingITAR Notice
This facility and its technical data are subject to U.S. export control laws. All visitors require advance approval.
Engage Forge
Two paths. One question: what does your program need this week?
Primary Conversion Path
A Forge program manager reviews every brief request personally. Response within 4 business hours.