Secure Edge
Authorized technical data ingest, revision/configuration control, digital traveler, role-based access, local storage and audit trail designed for disconnected operation.
ILLUMARIS PROGRAM • ADVANCED MANUFACTURING
FORGE
Secure point-of-need metal parts manufacturing for adaptive sustainment, advanced manufacturing and distributed maintenance.
THE MISSION PROBLEM
The part may exist in the supply chain. That does not mean it is available where or when it is needed.
Distributed operations expose long lead times, obsolete components, depot backlogs and fragile supply chains. A precision machine alone does not close that gap. Technical-data authority, process planning, tooling, material, robotics, cyber controls, inspection, traceability and release authority must operate as one system.
FORGE targets that integration problem.
THE CONCEPT
A controlled path from authorized technical data to a quality-released part.
FORGE is not a new CNC machine. It is a vendor-agnostic systems architecture that integrates mature commercial manufacturing technologies into a secure, disconnected-capable workflow for selected low-volume repair and replacement parts.
01AUTHORIZEApproved technical data enters a controlled local workflow.
→02PLANRevision, traveler, tools, material and process are coordinated.
→03MAKECommercial CNC and robotic handling execute the bounded job.
→04VERIFYProbing and independent metrology create traceable evidence.
→05RELEASEA human quality authority makes the final release decision.
FORGE STACK
Mature subsystems. Defense-specific integration.
Manufacturing
Commercial multi-axis CNC, robotic load/unload, tooling, workholding, raw stock management and in-process probing selected to fit the mission.
Quality
Independent metrology, material/process traceability, serialized quality records and an explicit human QA release gate.
Deployment
Packaging for protected sustainment nodes, utility and environmental interfaces, training, maintenance access and a vendor-agnostic technology refresh path.
WHERE IT FITS
FORGE complements additive manufacturing.
Additive manufacturing is an important part of the distributed manufacturing toolkit, but many legacy metal parts still require subtractive machining, repair operations, finish machining, tight tolerances or high-quality surface finishes. FORGE extends point-of-need manufacturing into those use cases while preserving traceability and release discipline.
The initial operating concept is for depots, theater sustainment areas and protected logistics nodes—not an unsupported claim of immediate frontline container manufacturing.
QUALIFICATION LADDER
Expand the part envelope with evidence—not optimism.
FORGE starts with bounded, low-consequence demonstrations and adds qualification requirements as the consequence and complexity of the part family increase.
Surrogates / Simple Non-Critical Parts
Prove workflow, repeatability, traceability and basic system integration.
Approved Low-Consequence Part Families
Add material pedigree, process templates, inspection plans and customer QA criteria.
Higher-Consequence Applications
Add machine/process qualification, special controls and part-family-specific evidence as required.
Distributed Qualified Catalog
Scale approved part families across qualified sites using controlled interfaces and documented release rules.
PROTOTYPE TARGETS
Measured against agreed baselines—not presented as validated field results.
≥50%Target lead-time reduction for selected demonstration parts
≥30%Target reduction in validated repetitive operator touch labor
≥90%Target first-pass dimensional acceptance on stable validated runs
100%Target traceable demo record linking data, material, process, inspection and release
These are prototype objectives to be measured during controlled demonstrations. They are not claims of current operational performance.
CYBER & DATA
Resilience without creating a new digital dependency.
Early demonstrations can remain unclassified and use authorized, non-sensitive technical data. FORGE is designed around a local, role-controlled edge workflow and a future security boundary suitable for contract-specific RMF/CMMC implementation when Controlled Unclassified Information is introduced.
Government-furnished technical data remains Government-controlled and is used only as authorized. Commercial OEM software retains applicable commercial rights. Illumaris intends to separate integration architecture and newly developed software from third-party intellectual property and to document interfaces wherever practical.
DUAL-USE POTENTIAL
The same integration problem exists outside defense.
Remote operations lose money when a critical part cannot be sourced quickly. FORGE's commercial opportunity is the integration architecture, secure/disconnected workflow, deployment package, qualification playbook and lifecycle support—not ownership of a proprietary machine tool.
Remote energy & miningMaritime / offshore MROAerospace maintenanceIndustrial obsolescenceUtilitiesDisaster recovery
TEAMING MODEL
Illumaris leads the architecture. Specialists bring mature equipment.
Machine Tool & Automation
Commercial CNC, robot, controls, workholding, tooling and lifecycle support providers.
Metrology & Quality
Independent dimensional inspection, scanning, quality system support and qualification expertise.
Cyber & Site Integration
Network segmentation, future CUI boundary, utilities, installation, acceptance and sustainment support.
FORGE