We digitize obsolete mechanical geometry and fabricate structural-grade carbon fiber replacements — bypassing months of OEM backorders in days.
Waiting months for an OEM backorder, or being forced to replace an entire $10,000 assembly over a single shattered plastic gear, is bleeding your operation dry.
Drag the slider to compare a factory-failed OEM component against our reinforced carbon fiber replacement.
Deliver your broken OEM component to our Frisco facility. We measure physical dimensions and structural load-bearing lines.
We extrude a rapid PLA test prototype and deliver it for physical mounting. You verify clearance and alignment with zero risk.
Upon fitment sign-off, we print the final part in carbon-fiber nylon (PA612-CF) followed by a 16-hour thermal annealing run.
We engineer solutions based on the absolute physical operating environment—heat, impact, and chemical exposure—exceeding original factory material specifications.
Chopped carbon fiber suspended in a nylon matrix. Extreme rigidity for load-bearing applications where factory ABS shatters under stress.
A mandatory 16-hour thermal cycle maximizes polymer crystallization. The result: parts that survive continuous operation in engine bays and industrial heat.
Ultrasonic brass heat-set inserts embedded directly into the matrix for permanent, repeatable bolted connections. No plastic threads. No stripping.
Text a photo with a ruler for scale. We'll tell you if we can rebuild it — no commitment.
Precision measurement of the failed component using analog and digital instruments. We extract exact geometric data from fragments.
Digital reconstruction in parametric CAD. We don't just copy the broken geometry — we isolate the failure point and reinforce it.
Immediate PLA fit-testing. We produce a rapid physical prototype and mount it on the machine for zero-risk geometric tolerance verification before final material commitment.
High-temp extrusion of Carbon Fiber Nylon followed by a mandatory 16-hour thermal annealing cycle to guarantee structural integration.
Strict scope, process, and IP policies. No exceptions.
No. Forge exclusively engineers structural, industrial-grade mechanical components. We do not produce toys, models, or aesthetic consumer goods.
You don't pay for Phase 2 until you physically prove it fits. The Phase 1 Engineering Fee includes up to two rapid PLA fit-test prototypes. We hand you a cheap plastic version of the geometry to mount on your machine. We only execute the high-cost carbon matrix extrusion after you sign off on the dimensional tolerance.
No. While CAD and PLA fit-tests happen rapidly, the final Carbon Fiber part requires a mandatory 16-hour thermal annealing cycle. Physics dictate the schedule.
You retain full ownership. We deliver parametric STEP, IGES, and native CAD files upon Phase 1 completion.
We can reconstruct it. If you provide the fragments and the surrounding assembly, we use metrology to establish the mounting points and Parametric CAD to rebuild the geometry.
Your entry point. We validate the geometry before you commit to production.
Billed only after your PLA fit-test sign-off. Cost is based on material weight and thermal runtime.
An obsolete alternator bracket was stalling a $10,000 restoration project. We delivered a reinforced carbon fiber replacement in 4 days.
Submit details about the mechanical failure. The engineering team will review the geometry and respond within 12 hours.
On the floor? Text a photo of the broken part next to a tape measure directly to our engineering queue for rapid triage.
TEXT: (214) 899-8228We operate in Frisco, TX. Local fabrication means rapid iteration, same-day test fitting, and no overseas shipping delays.