Capabilities
Six process families, built around one question: can you hold it at rate?
Anyone can make one good part. Everything below exists to make the ten-thousandth part identical to the first — the fixturing, the gaging, the tool management, and the engineering that happens before a single chip.
Multi-Axis Mill-Turn
Done-in-one machining of complex rotational parts. Main spindle, sub-spindle, B-axis milling head and lower turret work the part simultaneously, so a fitting that used to take four operations leaves the machine complete.
- B-axis contouring for compound angles and off-center features in one setup
- Synchronized main/sub-spindle transfer eliminates second-op fixturing
- Y-axis off-center milling, polygon turning, and thread whirling
- Bar feed and robot load for unattended second and third shift
Envelope & Specification
- Max turned diameter
- 26.4 in / 670 mm
- Max part length
- 59.8 in / 1,519 mm
- Bar capacity, through-spindle
- 4.0 in / 102 mm
- Simultaneous axes
- Up to 12
- Milling spindle
- 12,000 rpm / 30 hp
Simultaneous 5-Axis Milling
Trunnion and rotary-tilt platforms for structural and hot-section geometry — airfoils, impellers, manifolds, and monolithic brackets that cannot be reached on three axes.
- Tool-center-point control with full kinematic compensation
- Thin-wall and deep-pocket strategies for 7075 and Ti-6Al-4V
- Trochoidal and high-feed roughing on nickel alloys
- Palletized 5-axis cells for lights-out repeat production
Envelope & Specification
- Max envelope (X/Y/Z)
- 31.5 × 25.6 × 22.0 in
- Max swing
- Ø 25.6 in × 17.7 in H
- Table load
- 1,100 lb
- Spindle
- 18,000 rpm HSK-A63
- Rotary accuracy
- 4 arc-sec, direct-drive encoders
Precision Swiss Turning
Sliding-headstock cells for the small, high-count hardware that fills an aircraft — bushings, pins, studs, fasteners, and hydraulic fittings — at volumes where cycle seconds decide the price.
- Guide-bushing and non-guide-bushing modes for long or short work
- Live tooling, sub-spindle backworking, and full C-axis
- In-process laser and touch gaging with automatic offset correction
- Lot sizes from 500 to 100,000+ with SPC on every run
Envelope & Specification
- Bar capacity
- 4 – 32 mm
- Axes per machine
- Up to 12
- Diameter tolerance
- ±0.0002 in / 0.005 mm
- Surface finish
- To 8 µin Ra
- Bar loader
- 12 ft magazine, unattended
High-Volume Production Cells
Where Gemba Forge is built to win. Horizontal machining centers on pallet pools, tended cells, and process-controlled setups that run the same part to the same number for years.
- Dedicated fixturing and tool packages retained for repeat releases
- Kanban and min/max release against blanket POs and LTAs
- Tool-life management with sister tooling and automatic swap
- Kitted, bagged-and-tagged, serialized delivery to line-side
Envelope & Specification
- Pallet pool
- Up to 12 pallets per cell
- Unattended runtime
- 20+ hours
- Spindle uptime
- 85%+ on qualified programs
- Capability target
- Cpk ≥ 1.67 on all critical features
- Annual volume
- 500 – 250,000 pieces
Manufacturing Engineering
Every quote comes back with a process, not just a price. We work from model-based definition and tell you what will fight you before the first chip.
- DFM feedback on tolerance stack, access, and material selection
- Full machine-kinematic simulation before any part is cut
- Fixture and soft-jaw design built and proven in-house
- Process documentation, routers, and work instructions you own
Envelope & Specification
- CAM
- Mastercam, Esprit, hyperMILL
- Native CAD import
- CATIA V5, NX, SOLIDWORKS, Creo, STEP AP242
- Verification
- Vericut full-machine simulation
- Definition
- DPD / MBD with embedded PMI
- Fixture design
- In-house design and build
Finishing & Supply Chain
Managed through Nadcap-accredited partners under our AS9100 system, so a finished, certified part shows up at your dock with one packing slip and one PO.
- Nadcap-accredited special processors, flowed down and audited
- DFARS-compliant specialty metal sourcing with full traceability
- Certified mill test reports retained for program life
- Kitting, assembly, and consignment / VMI programs
Envelope & Specification
- Heat treat
- Solution, age, anneal, stress relief
- Anodize
- Type II & III, chem film per MIL-DTL-5541
- Plating
- Cad, nickel, zinc-nickel, passivate
- NDT
- FPI, magnetic particle, radiographic
- Marking
- Laser, dot-peen, UID / IUID
Tolerance & Finish
Held, not hoped for.
Standard is what we quote as routine. Capability is demonstrated with a study on your feature, in your material, on the machine that will run the job.
| Characteristic | Standard | Capability |
|---|---|---|
| Linear dimension | ±0.0010 in | ±0.0002 in |
| Turned diameter | ±0.0005 in | ±0.0002 in |
| Bore diameter | ±0.0005 in | ±0.0001 in |
| True position | 0.0020 in | 0.0005 in |
| Flatness / parallelism | 0.0010 in | 0.0002 in |
| Concentricity (TIR) | 0.0010 in | 0.0003 in |
| Angularity | ±0.5° | ±0.0028° (10 arc-sec) |
| Surface finish | 32 µin Ra | 8 µin Ra |
| Thread class | 2A / 2B | 3A / 3B, rolled or ground |
Thermal control
Inspection lab held at 68 °F ±2 °F. Production floor is climate-controlled, and precision work is soaked before final gaging.
Machine compensation
Volumetric and rotary compensation, ballbar verification on a scheduled interval, and spindle-growth compensation on long unattended runs.
In-process verification
Touch and laser gaging inside the machine with automatic offset correction, so drift is corrected before it becomes a nonconformance.
Materials
Including the ones that fight back.
Nickel and titanium are not exceptions here — they are a standing part of the mix, with proven tool packages, coolant strategies, and cycle data behind them. All specialty metal sourcing is DFARS-compliant with retained mill certifications.
Aluminum
- 6061-T6
- 7075-T651
- 7050-T7451
- 2024-T351
- 2219
- 5083
- AlBeMet
Stainless
- 15-5PH
- 17-4PH
- 13-8Mo
- 304 / 304L
- 316 / 316L
- 321
- 440C
- Nitronic 60
Nickel & Cobalt
- Inconel 718
- Inconel 625
- Waspaloy
- Hastelloy X
- A286
- Haynes 282
- MP35N
Titanium
- Ti-6Al-4V (Gr 5)
- Ti-6Al-4V ELI
- 6Al-2Sn-4Zr-2Mo
- CP Gr 2
- 5553
Alloy & Tool Steel
- 4140
- 4340
- 8620
- 9310
- 300M
- Maraging 250
- H13
Copper & Specialty
- Beryllium copper C17200
- C110 ETP
- Naval brass
- Invar 36
- Kovar
- Tungsten alloy
Engineered Polymers
- PEEK
- Vespel SP-1
- Torlon
- Delrin / acetal
- PTFE
- Ultem 1000
- G-10
Working in something not listed? Send it. We would rather run a test coupon and tell you what the material actually does than quote around it.
Production Scale
One supplier from qualification to rate.
Most programs change suppliers at least once between first article and full rate, and pay for a requalification every time. The point of this shop is that you should not have to.
- 01
Prototype
1 – 50 pcs
Soft-jaw and modular fixturing, programmed from your model. Days, not weeks — and the process notes carry forward.
- 02
Qualification
50 – 500 pcs
Production tooling and fixtures proven out. Full AS9102 first article and capability study on critical features.
- 03
Rate production
500 – 25,000 pcs / yr
Dedicated fixtures and tool packages retained. SPC live on key characteristics, releases against a blanket PO.
- 04
High volume
25,000 – 250,000 pcs / yr
Palletized and tended cells running lights-out, kanban replenishment, kitted line-side delivery.
Request for Quote
Send us the part everyone else quoted long.
Upload a model and a quantity. You will get back a price, a process, and an honest lead time — reviewed by the engineer who would run it.
AS9100D · ITAR Registered · CMMC Level 2 · CAGE 0ABC1