Dayton, Ohio · AS9100D · ITAR Registered
Complex parts.
Production volumes.
Gemba Forge runs 12-axis mill-turn and simultaneous 5-axis cells for aerospace and defense programs. We take the geometry other shops quote as a prototype and hold it to ±0.0002" — ten thousand parts in a row.
AS9100D
Certified QMS
ITAR
DDTC registered
CMMC L2
NIST 800-171
Cpk ≥ 1.67
On critical features
- Held tolerance
- ±0.0002"
- Axes
- 12
- Pieces / year
- 250k
- On-time delivery
- 99.6%
On critical features, temperature-controlled
Simultaneous, on our largest mill-turn cells
Sustained capacity across production cells
Rolling 12-month, all programs
Why Gemba Forge
Most shops are built for prototypes or for volume. We are built for the handoff.
The part that qualifies is the part that ships
Programs die in the gap between a hand-made first article and a repeatable process. We qualify on production tooling, in production fixtures, on the machine that will run the release — so a rate increase is a scheduling question, not an engineering one.
Fewer setups, fewer places to go wrong
Multi-axis mill-turn collapses four operations into one. Every setup you remove is a fixture that cannot shift, a datum that cannot drift, and a queue that cannot stall. That is where both the tolerance and the price come from.
Controlled and audit-ready
ITAR registration, access-controlled technical data, US persons on controlled work, and CMMC Level 2 controls on the network that touches your drawings. Compliance is a precondition here, not a project.
You talk to the people at the machine
No account layer between you and the process. When you call about a lot, you reach someone who has stood at that spindle. That is the whole idea behind the name.
Capabilities
Four process families, one quality system.
Every cell on the floor feeds the same routers, the same gaging discipline, and the same traceability record.
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.
- 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 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.
- 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
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.
- Bar capacity
- 4 – 32 mm
- Axes per machine
- Up to 12
- Diameter tolerance
- ±0.0002 in / 0.005 mm
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.
- Pallet pool
- Up to 12 pallets per cell
- Unattended runtime
- 20+ hours
- Spindle uptime
- 85%+ on qualified programs
Tolerance Capability
What we hold, and what we hold when it matters.
The standard column is what we quote without special handling. The capability column is demonstrated in our temperature-controlled inspection lab, with capability studies to back it.
| 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 |
Values at 68 °F. Tightest capability is material- and geometry-dependent — send the model and we will tell you exactly what is achievable on your feature.
Industries Served
Aerospace and defense, exclusively.
We do not split focus with automotive or consumer work. The whole shop is configured around programs that need traceability, configuration control, and a supplier still building the same part in year eight.
Aerostructures
Monolithic machined detail that has to be interchangeable across a whole airframe build rate.
2,000 – 100,000 pcs / yr
Engines & Propulsion
Hot-section and rotating hardware where material behavior, not the machine, sets the cycle.
500 – 25,000 pcs / yr
Defense Systems
Ground, naval, and munitions hardware under ITAR control, built to sustained rate with full traceability.
1,000 – 250,000 pcs / yr
Fluid & Actuation
Sealing-surface and bore work where finish and roundness decide whether the assembly leaks.
5,000 – 150,000 pcs / yr
Space & Launch
Low-rate, high-consequence hardware — and the sudden ramp when a program finds its cadence.
100 – 10,000 pcs / yr
Unmanned & Autonomy
Programs that need prototype speed first and a 10× rate increase eighteen months later, without changing suppliers.
1,000 – 200,000 pcs / yr
現場 · gen·ba · “the actual place”
The name is a commitment about where decisions get made.
In Japanese, 現場 is where the real work happens — the shop floor, the site, the scene. 現 (gen) means actual or present; 場 (ba) means place. Toyota made it a management principle: if you want to understand what is happening, go to where it is happening.
A forge is where pressure and heat turn raw material into something with the properties you actually needed. Both halves of the name describe the same conviction: the work, and the judgment about the work, belong in the same room.
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