Rank every viable AM process & material for your legacy part.
Upload a legacy part, set your goals and resources, and ForgeCast AI ranks every viable additive manufacturing (AM) process & material combination with model-based confidence bands and citations down to the datasheet row.
MMPDS-grounded · Walker-corrected fatigue · scatter-derived uncertainty
- ISO/ASTM 52900 (AM terminology)
- ISO/ASTM 52901 (AM purchase requirements)
- ASTM F3001 (Ti-6Al-4V ELI PBF)
- ASTM F2924 (Ti-6Al-4V PBF)
- ASTM F3055 (IN718 PBF)
- ASTM F3301 (AM post-processing)
- ASTM E8 (tensile testing)
- ASTM E466 (force-controlled fatigue)
- ASTM E606 (strain-controlled fatigue)
- ASTM E647 (fatigue crack growth)
Three audiences, one source of truth.
Stop guessing on process selection.
- Compare every viable process × material in seconds, not weeks.
- See fatigue and strength with scatter-derived 1σ uncertainty bands.
- Export a build recipe with parameters, supports, and lead-time.
Auditable, citation-grounded outputs.
- Every prediction links back to MMPDS, CMH-17, or vendor datasheet.
- Walker equivalent-stress correction with documented exponent assumptions, per alloy family.
- US-export-compliant alloys & vendors only; restricted technical data never leaves your tenant.
Quote legacy castings without the back-and-forth.
- Upload a CAD/STL and get unit-cost, lead-time, and risk in one view.
- Filter by your installed machines, gas, and feedstock inventory.
- Save projects, share with reviewers, export PDF reviewer packet.
Process selection used to take weeks. Now it takes a coffee break.
- Engineers stitch together MMPDS PDFs, vendor datasheets, and tribal Excel sheets
- Fatigue numbers used as-is, ignoring R-ratio of the actual service load
- Process candidates eliminated by gut feel before they're ever costed
- Spreadsheet trade-offs take 2–6 weeks per legacy part
- Every process × material combo ranked from a single CAD upload
- Walker equivalent-stress correction applied to mean-stress-sensitive fatigue cases
- Hard constraints + installed-equipment filter narrow the field automatically
- Ranked shortlist with cited recipes in seconds — review in minutes, exportable to PDF
Real parts, real decisions.
Hot-section bracket requalification
A legacy IN718 investment casting needs an AM replacement path. ForgeCast evaluates LPBF, DED-LB/M, DED-Arc (WAAM), and PBF-EB against the cast baseline, with HIP + solution + age post-processing assumed and Walker correction applied for the actual R-ratio seen in service.
Secondary structure bracket replacement
An obsoleted 7075-T7351 wrought bracket needs a drop-in AM replacement. The tool filters by US-export-compliant vendors, your installed machines, and available Ti-6Al-4V and AlSi10Mg feedstock — surface finish and HIP assumptions are pinned upfront.
Structural bracket consolidation
Multiple machined brackets consolidated into a single topology-optimized AM part. Fatigue and mass targets are set as hard constraints; cost is secondary.
From CAD to qualified recipe in five steps.
Upload geometry
Drop in your STL/STEP. Critical thickness, surface area, and overhang risk are computed in the browser. Your CAD never leaves the device.
Define goals
Slide weights for strength, fatigue, mass, cost, lead-time. Pin must-haves (e.g. minimum UTS) and the optimizer respects them as hard constraints.
Set environment
Operating temperature triggers a property derate vs. MMPDS / vendor elevated-temperature curves. Mean-stress ratio R drives a Walker equivalent-stress correction. Spectrum loads are reduced via rainflow + Palmgren–Miner damage summation.
Allocate resources & pin process assumptions
Select installed machines, gas, and feedstock. Pin build orientation, support strategy, surface finish (as-built vs. machined), HIP, and powder-reuse / oxygen-pickup limits — assumptions that dominate AM fatigue life. Candidates you can't run are filtered out, not silently scored low.
Get ranked recommendations
A ranked list with confidence chips, parameter recipes, and one-click compare. Export the top picks to PDF for review.
Real outputs, not slides.
These are live components from the app rendered with seed data. The same charts you'll generate from your own geometry.
Auditable, not just plausible.
Fatigue scoring & Walker correction
For mean-stress-sensitive fatigue cases, equivalent stress amplitude is computed using a Walker exponent fit per alloy and temper (not just per family). The exponent and a scatter-derived uncertainty band travel with every prediction. Alloys without a true endurance limit (e.g. AM Ti and Al) are scored on finite-life cycles, not a fictional fatigue limit.
Temperature derating & spectrum loading
Operating temperature triggers a property derate against MMPDS / vendor elevated-temperature curves. Variable-amplitude service loads are reduced via rainflow counting and Palmgren–Miner damage summation before fatigue scoring.
MMPDS-grounded, with AM caveats
Wrought and cast baselines reference MMPDS-2024 rows. AM-specific properties pull from vendor datasheets and peer-reviewed literature, since MMPDS AM coverage is limited and most published rows are wrought or cast. CMH-17 is used only for narrow metal-to-composite substitution screening.
Scatter-derived uncertainty bands
Every prediction ships with a 1σ band fit from datasheet and literature scatter — not a hand-wavy ±10%. These bands are model-based and will be re-calibrated as first-party coupon data is ingested.
Built for regulated work.
Defense primes and government program offices have specific guardrails. ForgeCast AI was designed around them from day one.
US export-compliance aware
The vendor and machine catalog is restricted to US-export-compliant entries; project tags drive a server-side filter, not a UI toggle a user can flip. ITAR / EAR controls hinge on end use and technical data — restricted technical data never leaves your tenant.
Geometry stays in your browser
STEP & STL parsing runs locally via WebAssembly. Your raw CAD file never leaves the device. Only scalar derived features and your project metadata are sent server-side for ranking (see next).
Exactly what the server sees
Server-side ranking receives only scalar feature summaries: mass (g), bounding box (mm), max & thinnest wall (mm), overhang area fraction, and projected build area (mm²). No mesh, no thickness map, no surface data — nothing reconstructible into your CAD.
Cited, reproducible outputs
Every number links to its MMPDS / CMH-17 source row with revision date. Exported PDFs include the full citation chain for stage-gate reviews.
Documented methodology
Built by Quantum Diffusion Corp. with a documented, reviewable methodology. Every assumption and correction is traceable to its source.
Every recommendation is grounded in a citable source.
No black-box scoring. The catalog is built on the same handbooks and standards your qualification reviewers already trust.
MMPDS-2024
Allowables for aerospace alloys. Every mechanical property in ForgeCast cites a specific MMPDS row. The Ti-6Al-4V standard-grade (ASTM F2924) vs. ELI (ASTM F3001) split is automatic: ELI is selected for fracture-critical or cryogenic service tags; standard-grade is the default otherwise.
CMH-17
Used narrowly for metal-to-composite substitution screening on legacy airframe brackets. Not used for AM metallic allowables.
NIST AM-Bench
Independent measurements of LPBF residual stress, melt-pool geometry, and distortion.
ISO/ASTM 52900-series
Process classification (52900), purchase requirements (52901), and qualification test methods used to score vendor capability. F42 is the ASTM committee that co-publishes these with ISO TC 261; we cite the standards, not the committee, in exported reports.
Vendor capability matrix
14 US-based service bureaus with audited machine inventory, build volume, and US-export-compliance status.
Beta estimates are model-based and not yet calibrated to measured test data. Confirm critical values with physical testing.
What's shipped, what's next.
Built in public. Beta users vote on what we prioritize next.
Ti-6Al-4V (std + ELI) & IN718 catalogs
MMPDS-2024 baselines plus AM-specific vendor datasheets, with the standard / ELI Ti-64 split tracked separately (per ASTM F2924 vs F3001). 14 US-export-compliant LPBF and DED-LB/M bureaus, with lead-time signals.
In-browser STEP/STL parser
WASM-based geometry analysis. CAD never leaves your machine.
Citation-backed PDF export
One-click reviewer packet with full MMPDS/CMH-17 citation chain.
AlSi10Mg & IN625 fatigue allowables
Promoting AlSi10Mg LPBF and Inconel 625 LPBF from screening-only to full fatigue-curve coverage with vendor-validated S–N data.
Vendor-specific cost calibration
Promote the current parametric cost model (machine-hour, powder, post-processing) from generic to per-vendor quotes, pulled directly from bureau rate cards.
Coupon-fed Bayesian calibration
Ingest first-party coupon test results to update recommendation priors per facility and per machine. (Not in-situ closed-loop control — that lives on the machine.)
Common questions.
What is the public beta?
ForgeCast AI is in active development. The beta is free, no credit card. Expect rough edges and incomplete catalog coverage — please report bugs to beta@qdlabs.tech.
What's actually "AI" about ForgeCast AI?
Honest answer: today, very little. The current ranker is a deterministic weighted sum over physics-based scores (Walker-corrected fatigue, MMPDS-derated strength, mass, cost, build-time) plus a geometry-fit heuristic and a confidence multiplier — there is no learned model in production. The "AI" in the name refers to the roadmap product: a Bayesian update layer (planned 2027) that recalibrates per-facility priors as first-party coupon data is ingested, and a learning-to-rank step trained on reviewer accept/reject signals collected during the beta. We'd rather be upfront about this than imply ML where there isn't any. Mechanical-property numbers are, and will remain, handbook lookups with documented corrections — never LLM-generated.
Is my CAD data uploaded to a server?
Your raw CAD file never leaves your device — STEP/STL parsing runs in the browser via WebAssembly. Only scalar derived features (mass, bounding box, max/thinnest wall, overhang area fraction, projected build area) and your project metadata (alloy, process, goals) are sent server-side so the ranker can run and so you can come back to your projects later. No mesh, thickness map, or surface data is transmitted.
What does it cost after beta?
Pricing is not yet finalized, but we commit to two things: (1) every beta account is grandfathered into a paid tier at a permanent discount, and (2) the free tier will remain usable for single-part exploration after GA — you won't be paywalled out of the tool you learned on.
Are export-controlled alloys included?
The vendor and machine catalog is restricted to US-export-compliant entries; restricted entries are excluded server-side, not just hidden in the UI. Note that ITAR/EAR controls generally hinge on end use and technical data, not on the alloys themselves — so we also commit that restricted technical data you enter never leaves your tenant.
Who is behind ForgeCast AI?
Quantum Diffusion Corp., focused on legacy-part qualification via additive manufacturing.
How do I share feedback?
Email beta@qdlabs.tech with your project ID and a short description. We triage bug reports within one business day during the beta.
Free during beta. Five minutes to your first ranked recommendation.
No credit card. Email confirmation required to verify your account.
Start free beta