FORGE
CONCEPT
Every build starts with a whiteboard and a deadline. In the first 24 hours, your napkin sketch becomes a parametric CAD model, a preliminary BOM, and a fabrication risk matrix.
Li-ceramic electrolyte stack, 12-layer laminate
Inconel 718, ±0.005mm tolerance, CFD validated
Phase-change material + vapor chamber hybrid
IP67 rated, DIN rail mount, EMC compliant
24-Hour CAD Blitz: Solid-State Cell Module
How a startup CTO's sketch became a 14-layer stack design in one day
DESIGN
FEA, CFD, thermal simulation — all running in parallel. Material selection locked by hour 48. Design freeze by hour 72. No iteration fog, no committee creep.
Parallel simulation pipelines cut design validation from weeks to hours. Every geometry is stress-tested before a single chip of metal is cut.
72-Hour Design Sprint: Micro-Turbine
FEA + CFD in parallel, material locked by hour 48
FABRICATION
Chips fly at 6 a.m. Every machine runs a countdown to ship date. Live feed rates, layer counts, and tolerance checks stream to your project dashboard.
5-Axis Machining: Turbine Housing in 72h
Inconel 718, ±0.005mm — from G-code to part in three days
TEST
Load cycles, thermal imaging, electrochemical impedance, vibration sweeps — all running before you land from your last flight. Data streams to your dashboard in real time.
EIS + C-Rate Testing: 48h Validation Protocol
Full battery characterization before DOE review gate
DELIVER
Day eleven. Your prototype ships with a full test report, CAD files, BOM, and a 30-day engineering support window. No surprises at the gate.
"Solid-state cell module delivered in 9 days. Passed DOE Phase II review. Secured $4.2M Series A close."
"Micro-turbine housing prototype cleared quarterly milestone. Thermal runaway containment validated."
"Thermal management rig delivered 3 days before review gate. PI cited Forge in grant renewal."
The Forge Prototyping Playbook
47 pages. Every phase of the 11-day build process, tolerance specs, material selection matrices, and test protocols used on 140+ energy hardware builds.