Cell, Plant and Enterprise. The Cell tier covers one control, die or inspection module on one forging or heat-treat cell or line. Plant covers the whole forge. Enterprise is for multi-site groups. Annual prepay carries a 15 to 20% discount and outcome components are available on yield, scrap, die life and energy.
Floor pricing is protected. Discounts are traded for term length and a published case study.
Land on one workflow with a measured baseline. Expand by cell, module and autonomy level. Outcome components are available on yield, scrap, die life and energy. Annual prepay carries a 15 to 20% discount.
Heating or forging control, die management, or inspection AI for one cell. For forges validating ROI on the wedge.
The whole forge: heat and billet, forge and press, die and lube, trim and heat-treat, defect, quality and property, yield and takt, robotic handling and the twin.
Multi-site forging groups standardising on Forgiron, with custom alloy, die and qualification models.
Products are licensed per cell on the Cell tier and bundled on Plant and Enterprise.
| Capability | Cell | Plant | Enterprise |
|---|---|---|---|
| Cells covered | 1 | All on site | All in group |
| Agent modules | 1 of 6 products | All agents | All agents + custom models |
| As-forged twin (Forgetwin) | No | Included | Custom part-family twins |
| Plant-edge node | Included | Per cell | Fleet managed |
| Guarded controller writes | Scoped tags | All scoped tags | Group policy |
| Forging genealogy | Included | Included | Included + qualification packets |
| Autonomy levels | L1 to L2 | L1 to L3 | L1 to L4 when qualified |
| SSO and RBAC | No | Planned | Planned, with approval chains |
| On-prem deployment | No | Optional | Included |
| Support | Business hours | 24/7 | 24/7 + named engineer |
| Indicative price | $15,000/mo | $90,000/mo | $650k to $8.5M ACV |
We do not publish savings percentages because we have not measured any yet. These are the inputs a forge brings to the pilot baseline, and the outputs the pilot measures.
A run engine that produces this record on every lot, every shift, on every cell you license.
Plant Orchestrator · Pulled the part spec for the 42CrMo4 connecting rod from MES: forging window 1,180 to 1,230 °C, two-blow closed-die schedule, flash land 2.4 mm, temper to 28 to 32 HRC, 1,200 pieces. Locked the qualified process envelope.
Forge Twin · Simulated 24 candidate heat-and-stroke recipes on the as-forged twin for soak time, blow energy and spray timing, ranked on predicted fill, lap risk at the flash land, die load and kWh per piece.
Heat-and-Billet · Induction power on IH-2 stepped down 4% in the final soak stage as the pyrometer read 1,205 °C at the surface. Core-to-surface spread estimated at 14 °C against a 20 °C limit, no overheat, scale growth inside the window.
Die-and-Lube · Lower-die spray dose raised 6% and cooling extended 0.3 s as die surface temperature climbed through 240 °C. Heat-check growth on cavity 2 flagged at 0.31 of the die-change threshold.
Plant Orchestrator · Recipe #9 moves second-blow energy 3% below the standing schedule. Press-schedule changes stay supervised on this part family, so the step was held for the shift forging engineer and approved at 05:47:31.
Forge-and-Press · Two-blow schedule executed with the approved energy. High-speed vision and force curves confirmed complete fill on the first ten pieces; predicted lap risk at the flash land fell from 0.27 to 0.08.
Defect-and-Inspect · Eight cameras, two thermal cameras and the ultrasonic station fused at the edge. One lap precursor at the flash land on piece 212 flagged and cleared by a 1.5% blow-energy trim inside the approved envelope; the piece was routed to MPI and passed.
Robot-and-Handling · Press-to-trim transfer planned and executed by the handling robot at 11 s per piece, temperature loss in transfer 38 °C against a 60 °C limit, interlock zones clear throughout.
Trim-and-Heat · Temper furnace HT-1 zone 2 trimmed 5 °C against the predicted hardness from the recorded heat and stroke history. First hardness checks read 30 HRC, inside 28 to 32.
Quality-and-Conformance · Lot L-80412 released: genealogy written (billet lot, heat curve, stroke record, die cycles, inspection map, approvals, temper record) and dispositioned against IATF 16949 criteria with cited evidence for the quality engineer's sign-off.
Automotive and driveline, aerospace and defense, energy, industrial forgings, ring rolling and open-die. Most forges pick one cell and one wedge, prove the number, then expand.
Crankshafts, connecting rods, gears, axle and suspension parts at rate. Heatrix and Diesmith on the highest-volume cell first, where scrap and unplanned die changes are already counted.
Turbine and engine discs, landing gear and structural forgings under AS9100 and NADCAP. Flawnex on the inspection line, with genealogy and cited disposition from day one.
Turbine, oil and gas and nuclear forgings where a single internal defect is catastrophic. Flawnex and Forgetwin on the part family with the longest qualification cycle.
Closed-die and upsetting lines making industrial parts in many alloys. Forgeon and Diesmith on the press cell with the most changeovers.
Rings and open-die forgings where billet heating is the energy bill and the stroke count is high. Heatrix first, then Forgeon on the mill.
Forgiron writes to production equipment. Every capability is scoped, every write is policy-checked against the qualified envelope, and every action is written to an append-only audit log the forge owns.
| Item | Scope | Status |
|---|---|---|
| SOC 2 Type I | Cloud control plane | QUEUED Planned, first 6 months |
| SOC 2 Type II | Cloud control plane | QUEUED Planned, 6 to 12 months |
| SSO and RBAC | Console and approvals | QUEUED Planned, 6 to 12 months |
| AS9100 and NADCAP assurance packages | Disposition and genealogy evidence | QUEUED Planned, 6 to 12 months; not a certification claim |
| Standards-cited reasoning | AS9100, IATF 16949, NADCAP, ASTM documents | RUNNING In the design, every answer cites its source |
| Per-tenant and die-IP isolation | Recipes, die designs, models, memory | RUNNING In the design from day one |
| On-prem and plant-edge deployment | Sensitive producers | RUNNING Design option |
One policy model, one audit trail, one benchmark across every cell in every forge, with the alloy, die and qualification models kept private to each site.
The questions plant directors, forging engineers and quality engineers ask in the first meeting.
Yes, but only within an explicit tag allow-list with per-tag rate and magnitude limits, inside the qualified process envelope, and only at the autonomy level your plant has set. Design partners start in shadow mode, where Forgiron writes nothing. Press-schedule changes stay supervised by a named forging engineer until the part family is qualified.
Control returns to the furnace, press or die controller's last known-good state. Forgiron is a supervisory layer on top of the PLCs and interlocks you already run, never a replacement for them, so an outage degrades the cell to its current way of running, not to a stop.
Advisory recommendations start from the physics-based twin and the part spec in the first weeks. Defect, die-wear and heating prediction improve as cell history and labelled outcomes accumulate per part family. The first training sets are sized at 2 million labelled frames and signals, 20,000 heat and press cycles and 10,000 die-life events per design-partner cohort, all design targets.
Only if you choose cloud training. Die designs, part drawings, recipes, process models and quality records are isolated per tenant and never used to train another customer's models. A fully on-prem deployment at the plant edge is available for sensitive producers, and federated learning across sites is planned and waits on data-rights agreements.
You are, the same as with any control strategy, which is why every write is policy-checked, bounded, logged and reversible, and why anything above your risk threshold waits for a named approver. The audit log records the request, the evidence, the envelope applied and the human decision.
A paid pilot of 90 to 180 days on one cell, scoped to a single wedge with a success metric written into the order form: defect-detection accuracy, scrap reduction, die-change reduction, energy reduction or first-pass-quality improvement. The first 30 to 60 days baseline scrap, die life, energy, inspection escapes and takt in shadow mode.
Start with one heating, press, die or inspection cell and one measurable baseline. A paid pilot on billet heating and press fill, die life or ultrasonic and MPI defect detection shows the number before you commit further.
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