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Engineering and Advanced Manufacturing for Commercial Markets

Who We Serve

Agencies responsible for National Security, including DoD and Intelligence Communities, State Department, and DHS in ground, sea, air, space, and cyber operations.

Problems We Solve

Advanced Manufacturing: R&D through Production

AFORGE’s Engineering and Advanced Manufacturing services are built around one goal: getting your operation critical systems ready for rapid production, better than before. Clients across industries like industrial, aerospace, defense, automotive, and food and bev turn to us when they need:
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Reverse Engineering

We are your obsolete parts solution provider. Whether you have damaged or legacy parts, we conduct full 3D scanning and modeling to create high-fidelity digital replicas ready for reproduction or improvement.

Comprehensive Data Capture and 3D CAD Development

We provide expert consultation translating raw data into intelligent design files to refine functionality and performance.

Design Verification and Engineering Support

Our team collaborates closely with yours to prototype, test, and iterate until the part is proven and production-ready.

Beyond Prototypes: Scalable Manufacturing

While we can support single-unit prototyping, our real strength lies in delivering scalable, repeatable, and cost-effective production runs - on your timeline.
Photo By: EJ Hersom, DOD

Tailored Solutions

Customers rely on AFORGE to not only produce a part, but to solve their problem. Whether it’s a broken component, an outdated system, or a supply chain gap, we specialize in helping our partners define the issue, develop a solution, and move quickly from concept to production.
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Client Examples

Photo By: Navy Petty Officer 2nd Class Elliot Schaudt

Small
Arms

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Fabrication Partners

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Photo By: Marine Corps Staff Sgt. Donato Maffin

Food & Beverage Equipment

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Photo By: Marine Corps Staff Sgt. Donato Maffin

Automotive Parts

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Engineering and Advanced Manufacturing Capabilities

Produce high-quality precision products with short lead times in mission critical environments.

AFORGE AM incorporates a range of innovative techniques such as automation, robotics, additive manufacturing (3D printing), artificial intelligence, internet of things (IoT), and data analytics paired with decades of in-theater experience for fast results at the speed of relevance.

Design / Engineering Services

  • CAD design, DFAM, generative design, topology optimization
  • Simulation: static FEA and CFD
  • 3D scanning: data collection at a resolution of 0.02um (micron)
  • Reverse engineering: 3D CAD generation from scanned data
  • Metrology grade inspection and dimensional analysis from scanned data or CMM contact-based measurement

Advanced Manufacturing

  • Additive metals: tool steels, stainless steels, IN625, IN718, Ti-6Al-4V, CuCrZr, Al, CoCr, and more
  • Additive polymers: nylon 6, 11, and 12. Carbon fiber and glass bead composites available
  • Subtractive CNC 5 axis, CNC lathe, and EDM

Supportive Manufacturing Processes

  • Resin-based DCPD ballistic armor- custom form-fitting up to IV+
  • Precision Laser Welding

Schedule a Strategy Assessment Consultation Today

Protecting our national security interests is not something we take lightly. With over 25 years of average mission experience in active duty US military, Department of Defense, and the intelligence community, we understand each agency's unique requirements, processes, and systems. Schedule a Strategy Assessment Consultation today to see how we can advance your national security objectives by deploying smarter, faster, and leaner technology solutions.
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