We digitize obsolete mechanical geometry and fabricate structural-grade polymer replacements, instantly bypassing critical supply chain failures.
Waiting months for an OEM backorder, or being forced to replace an entire $10,000 assembly over a single shattered plastic gear, is a catastrophic financial bleed.
We engineer solutions based on the absolute physical operating environment—heat, impact, and chemical exposure—crushing standard factory ABS specifications.
PA612-CF suspends chopped carbon fiber within a nylon matrix, providing extreme rigidity for massive load-bearing applications.
A strict 16-hour thermal processing cycle maximizes polymer crystallization. This process guarantees survival in a hot engine bay.
We integrate ultrasonic brass heat-set inserts directly into the matrix for repetitive bolting, refusing to rely on weak plastic threads.
Precision measurement of the failed component to capture physical dimensions. We extract exact geometric data from shattered fragments.
Digital reconstruction via Onshape. We don't just copy the broken part; we isolate the structural weakness and reinforce the failure points digitally.
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.
A low-risk gateway to full fabrication. Establishes the exact geometric requirements before heavy production costs.
Billed only upon your final PLA fit-test approval. Final cost is calculated strictly on polymer weight and machine thermal runtime.
A custom auto shop handed us an obsolete alternator bracket holding up a $10,000 restoration job. We eliminated the backorder in 4 days.
No. Forge exclusively engineers structural, industrial-grade mechanical components. We do not produce toys, models, or aesthetic consumer goods.
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.
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.
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.
You retain full ownership. We deliver parametric STEP, IGES, and native CAD files upon Phase 1 completion.
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) 899-8228Forge operates locally in North Texas. We bypass global supply chain shipping delays, offering rapid physical iteration, test-fitting, and delivery that overseas manufacturers cannot match.