AS9100D CERTIFIEDITAR REGISTEREDNADCAP APPROVEDCMMC LEVEL 2

Qualified.Traceable.On Schedule.

Precision machining for mission-critical defense programs. Turbine housings, armored enclosures, and avionics mounts held to ±0.0003″ — with full first-article documentation and ITAR-compliant traceability from raw billet to final inspection.

0.00%
Lot Rejection Rate
14,000+
Flight-Critical Parts
±0.0003″
Positional Tolerance
3D Inspection Station — Live View
DWG-2026-TH-001
MAT: AMS 5662Inconel 718 · STAFINISH: 16 Ra μinCMM Verified · 100%POS TOL: ±0.0003″GD&T per ASME Y14.5HARD: 38-42 HRCCert of ConformanceDATUM REF FRAME: A-B-C · THIRD ANGLE PROJECTION · UNITS: INCHES
REVISION: D · APPROVED: 2026-02-26◉ CMM VERIFIED
Scroll
Program Performance · FY2022–2026
DATA SOURCE: INTERNAL QMS · LAST AUDIT: 2026-01-14
0.00%
Lot Rejection Rate
14,000 flight-critical parts delivered
0%
On-Time Delivery
Across all CDRL deliverables
0+
Flight-Critical Parts
Zero in-service failures
0
Defense Programs
Active concurrent programs, FY2026
All performance data subject to AS9100D QMS audit · ITAR-controlled distribution
Program Record 01 / 03
Classification: Unclassified
The Problem

Turbine Housing Program —
Supplier Failure at LRIP Gate

A Tier 1 prime's incumbent machine shop failed first article inspection on the GE-derived turbine housing — 23 of 48 critical dimensions out of tolerance on the initial FAI submission. With LRIP scheduled to begin in 11 weeks, the program manager needed a qualified replacement that could absorb the drawing package, complete DFM review, and deliver conforming first articles in time to hold the production milestone.

The Process
D+2DFM review complete. Identified 4 features requiring fixturing redesign to achieve ±0.0003″ positional callouts on the split-line bolt pattern.
D+8Inconel 718 billet (AMS 5662, STA condition) sourced from qualified domestic mill. CoC on file. ITAR export control screening completed.
D+31First article machining complete on 5-axis DMG Mori NHX 5000. 100% CMM inspection using Zeiss Contura — all 48 critical dimensions in tolerance.
D+38FAI package submitted: AS9102 Rev B format, full ballooned drawing, dimensional report, material certs, heat treat records, surface finish data.
The Outcome

FAI approved in 38 days from drawing receipt. LRIP milestone held. 312 housings delivered across 6 production lots with zero lot rejections. Program manager added Forge to the prime's Approved Vendor List within 60 days of first delivery.

First Article Inspection Report
FAI-2024-TH-001
Part NumberTH-4892-C-ASSY
MaterialInconel 718 · AMS 5662
Heat TreatSTA per AMS 2774
Surface Finish16 Ra μin · 100% verified
Critical Dimensions48 of 48 conforming
Positional Tolerance±0.0003″ achieved
Hardness38–42 HRC · lot cert on file
CMM EquipmentZeiss Contura G2 · Cal 2026-03
Ballooned DrawingComplete · AS9102 Rev B
FAI StatusAPPROVED — D+38
312Units Delivered
0Lot Rejections
3 WksAhead of Schedule
Full FAI package available under NDA · ITAR-controlled distribution
Manufacturing Capabilities
Core Competency

5-Axis Simultaneous
Precision Machining

Complex geometries held to blueprint. Every feature CMM-verified before the part leaves the machine. No exceptions for flight-critical hardware.

Positional Tolerance
±0.0003″
ASME Y14.5 · GD&T
Surface Finish
8 Ra
μin achievable
Materials QualifiedCert on File
  • Inconel 718 · AMS 5662
  • Titanium 6Al-4V · AMS 4928
  • Steel 4340 · AMS 6414
  • Aluminum 7075-T651 · AMS 2770
  • Stainless 17-4 PH · AMS 5643
  • Beryllium Copper · ASTM B196
CNC Equipment
  • DMG Mori NHX 5000 · 5-axis simultaneous
  • Mazak Variaxis i-700 · 5-axis mill-turn
  • Haas ST-40 · CNC turning center
  • Makino a61nx · HMC, pallet system
  • Zeiss Contura G2 · Bridge CMM
  • Renishaw Equator · Gauging system
Certifications & Compliance
AS9100DQMS Certified
ITAR22 CFR 120-130
NADCAPSpecial Processes
CMMCLevel 2 Compliant
ISO 17025Lab Accredited
DFARCompliant Supply
Component Types
  • Turbine housings & compressor cases
  • Armored enclosures (MIL-SPEC)
  • Avionics mounts & EMI housings
  • Hydraulic manifolds & valve bodies
  • Missile guidance structures
  • Optical bench assemblies
Full Traceability Chain
01Raw BilletMill cert · heat lot · CoC
02In-ProcessOp-by-op inspection records
03Heat TreatTime-temp charts · hardness cert
04Final CMM100% critical dimension report
05ShippingDD250 · packing list · CoC package
Floor Capacity
24/7
3-shift operations
28,000 sq ft facility
14 CNC machining centers
Dedicated metrology lab
17 Wks
Qualification Timeline
MIL-DTL-38999 connector housing · typical industry: 28 wks
0.00%
Defect Rate
Across 6,200 avionics mount assemblies delivered
$2.4M
Re-work Cost Avoided
DFM intervention on armored enclosure program
Program Record 02 / 03
Classification: Unclassified // Releasable
Qualification Data Package
QDP-2025-AM-003
Qualification Milestone Schedule
Drawing Receipt & DFM ReviewW+1W+1COMPLETE
Tooling & Fixture DesignW+3W+3COMPLETE
Prototype Machining (3 pcs)W+7W+6AHEAD
Environmental Test SamplesW+10W+9AHEAD
First Article InspectionW+14W+13AHEAD
Qualification ApprovalW+20W+17AHEAD
MilestonePlanActualStatus
3 Wks EarlyQualification Complete
6,200Units Delivered, Zero Defects
The Problem

Avionics Mount Redesign —
Accelerated Qualification Under LRIP Pressure

An avionics integration team redesigned their MIL-DTL-38999 connector housing mount mid-program after EMI testing failures revealed resonance at 400 Hz. The redesign required re-qualification of the titanium machined structure — with LRIP already scheduled and the program office unwilling to slip the production milestone.

The Process
DFMForge engineering reviewed the redesigned geometry and identified that the original wall thickness spec (0.080″) was unmachineable to tolerance on the pocket radius. Recommended 0.095″ — approved by the customer's stress team within 48 hours.
FIRST ARTICLE6Al-4V titanium billet sourced from domestic mill with AMS 4928 cert. 5-axis program written and proven on 3 prototype pieces. All 47 critical dimensions conforming on first submission. No iterations.
QUALVibration and thermal test samples delivered to customer test lab in Week 9. Qualification approval received Week 17 — 3 weeks ahead of the contractual milestone, holding the LRIP start date.
The Outcome

Qualification approved 3 weeks ahead of schedule. 6,200 mount assemblies delivered across 8 production lots with zero dimensional rejections and zero in-service failures. The program office cited Forge's DFM intervention as directly preventing a $2.4M re-work event.

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