There is a critical need for forged components across all DoD services, ranging from small to extra-large components. The forging supply chain is identified as a critical vulnerability for the DoD due to factors including traditionally high-mix low-volume demands, limited domestic capability for aerospace-quality forgings, a dwindling domestic workforce, and a limited ability for manufacturing surge. These factors lead to significant lead times (up to 36 months) for components resulting in diminished military readiness. In the far term, there exists both an inability for forging component suppliers to meet the increasing demand for quality DoD forgings and to meet wartime surge demands, which could impact operational capabilities.
Incremental robotic forging offers a solution to these challenges. By leveraging advances in automation and artificial intelligence, an industrial robot can act as a skilled “blacksmith”, operating an open die forging system to produce a wide variety of forged geometries using a single system.
This approach:
- Enables arbitrary geometries (traditionally closed-die forged) to be manufactured in an open-die process.
- Could be applied to many traditionally forged alloys.
- Provides an end-to-end solution for insertion at various points along the DoD manufacturing supply chain.
This project will mature an autonomous robotic system for incremental open die forging of bulk metal components. The system’s capability will be assessed on its ability to manufacture forged components of need for multiple DoD services, including the Army, Air Force, Navy, and Defense Logistics Agency.
Proposals for this Project Call are due on December 3, 2025 at 5:00 PM ET and must be submitted via the ARM Member Community. While our Project Call is publicly available, you must be an ARM Member to submit a proposal. Learn more about membership here.