Forg3D: Sovereign Additive Manufacturing for European Defence and Aerospace

Forg3D is redefining how critical metal parts are made, bridging traditional forging quality with cutting-edge 3D printing innovation. This young company has emerged from Europe’s advanced manufacturing frontier with a bold mission: to replace slow, inefficient casting and forging processes with a smarter, agile alternative. Specializing in large-scale Wire-Arc Additive Manufacturing (WAAM), Forg3D’s proprietary technology can print large metal components on demand, dramatically shrinking production lead times from months to days.

Such capability is more than an engineering feat – it promises to bolster Europe’s strategic autonomy by reshoring the supply of mission-critical aerospace and defence parts. The company’s ambitions reach from factory floor to field deployment and even into orbit: its mobile “3D forge” units aim to manufacture or repair metal components anywhere – whether on a remote military base or a lunar outpost. Forg3D stands at the intersection of innovation and sovereignty, offering a glimpse into a future where Europe can sustain its own defense industrial needs with homegrown technology.

Forg3D is a deep-tech startup (United Kingdom) pioneering large-scale metal additive manufacturing for aerospace, defence and space applications. It developed a patented WAAM-based process that combines robotics, AI-driven controls, and advanced metallurgy to produce “3D forged” metal parts with the strength of traditional forgings. This aligns squarely with European emerging technology priorities in Advanced Materials & Manufacturing, while also leveraging autonomous systems and AI for process automation.

By enabling on-demand production of critical components – from aircraft structures to naval spare parts – Forg3D contributes tangible value to European strategic autonomy. Its technology can substitute extra-EU suppliers in key supply chains (e.g. large titanium or Inconel alloy parts), reducing dependency on foreign forging providers. Participation in NATO’s DIANA accelerator and UK defence-energy programs attests to its interoperability and dual-use potential, supporting NATO logistics resilience and European deterrence.