Factory Intelligence for Real Production
ForgeSense™ is a modular AI platform that turns CNC floors into self-optimizing, connected manufacturing systems. It blends predictive, generative, and agentic intelligence to simplify programming, catch defects in real time, protect tools, and orchestrate end-to-end digital job execution.
Why ForgeSense™?
- AI-assisted programming from CAD/SVG reduces G-code errors and cuts setup time.
- Adaptive toolpath logic removes operator-dependent variability and improves repeatability.
- Real-time AI vision catches defects during the run, not after the batch.
- Predictive maintenance alerts prevent tool damage and unplanned downtime.
- Sensor-driven feedback replaces static parameters and continuously optimizes feeds and speeds.
- Operator friendly with a co-pilot and embedded learning to shorten onboarding and reduce errors.
How it works
ForgeSense™ connects machines, data, and people into a closed learning loop, plan, simulate, execute, and improve on every run for safer, faster, more consistent production.
- Data Integration: Connect controllers, sensors, MES/ERP, historians, CAD/CAM, and files into a single, synchronized stream.
- Insight Generation: AI analyzes geometry, process signals, and images to surface risks, opportunities, and quality hotspots.
- Decision Intelligence: Recommend toolpaths, parameters, and priorities before a job reaches the spindle, reducing trial-and-error.
- Automated Execution: Apply adaptive feeds and RPM with controller-safe adjustments in real time to protect tools and finish.
- Performance Analysis: Track quality, downtime, tool wear, and OEE across jobs, cells, and plants for clear accountability.
Key Modules of ForgeSense™
Engineered for safer planning, faster execution, and consistent quality.
Rapid CAD to Code Programming
• Converts SVG/DXF/STEP geometry into G/M-code using templates. • Detects features like holes, pockets, contours to suggest strategies. • Applies machine and material presets for feeds, speeds, coolant, safety. • Checks dialect and syntax to prevent alarms, mid-run stops. • Inserts tool calls, offsets, and start/end sequences automatically. • Tracks revisions, diffs so changes are auditable and reversible. • Publishes programs to machines and archives for traceability.
Simulate and Verify Before Cut
• Simulates 2D/3D toolpaths to verify collisions, clearances, travel limits. • Visualizes stock removal and chip load across the cycle. • Estimates cycle time and flags bottlenecks before floor release. • Validates soft limits, rotary reach, fixture interference. • Highlights gouges, overcuts, and tolerance risks on key features. • Generates setup sheets for fixtures, tools, and probing steps. • Runs what-if scenarios to compare tooling, parameters, fixturing.
Real-Time In-Run Defect Detection
• Detects defects and dimensional errors in-run via camera pipelines. • Learns from images and adapts thresholds as parts or lighting vary. • Measures features and flags anomalies using repeatable criteria. • Issues pass/fail alerts to HMI and updates part status in MES/ERP. • Logs images with timestamps, part IDs, program revisions for audit. • Supports multi-camera, variable lighting, and pose templates. • Operates at the edge offline; syncs results when connectivity returns.
Live Feeds and Speeds Optimization
• Reads vibration, load, temperature, and acoustics to guide adjustments. • Tunes feeds/RPM to protect tools and stabilize finish as load changes. • Enforces limits and overrides so controllers stay within OEM constraints. • Reduces cycle time without breaching quality or thermal thresholds. • Learns material- and tool-specific responses to improve each job. • Integrates via controller-safe channels for command and feedback. • Records adjustments for analysis, recipes, and future reuse.
Features of ForgeSense™
Built to boost insight, precision, and productivity.
AI-Assisted Programming
Cut programming time via geometry-to-code workflows and reusable templates for complex parts and repeat jobs.
Real-Time Quality Assurance
Detect defects and anomalies on the line-no more “after-the-fact” surprises, using live vision checks and operator alerts.
Predictive Maintenance
Monitor tool wear and vibration to prevent crashes and scrap, extending spindle life and maintenance intervals.
Adaptive Machining
Optimize surface finish and tool life with closed-loop parameter control that responds to load, heat, and chatter.
Digital Twins & Simulation
Validate jobs, visualize status, and de-risk changes before production with collision checks and cycle-time estimates.
Controller-Safe Integrations
Connect safely to controller ecosystems through OPC-UA and open connectors while preserving interlocks and warranties.
Shop-Floor Scheduling
Balance workloads and reduce idle time across machines and operators with smarter queues and constraint awareness.
Operator Enablement
Embedded assistant and Ed+ reduce training time and tribal knowledge gaps through guided steps and on-console tips.
Traceability & Reporting
Log data, parameters, tool events, and QC results as searchable reports for audits, certifications, and improvement.
Inspirational Insights Client Stories
Manufacturing case studies that move KPIs, not slide decks in real factories.
FAQs on ForgeSense™ Platform
Can ForgeSense™ work with legacy CNCs and older controllers in mixed fleets?
Yes. ForgeSense™ connects to mixed-brand and mixed-vintage machines through the Controller Bridge and open connectors (e.g., OPC-UA, serial/Ethernet adapters), so you don’t need to replace controllers. You can start with visibility-only mode, then enable safe commands over time while preserving interlocks and OEM safeguards.
Do we need AI expertise to use ForgeSense™, or is it operator-friendly?
No. Assistive programming, the operator co-pilot, and Ed+ micro-learning guide teams step-by-step, so shops and skill labs can ramp quickly. Templates, guardrails, and clear prompts help standardize best practices without requiring data science skills.
How does ForgeSense™ ensure data security and privacy across on-prem, edge, and cloud deployments?
ForgeSense™ supports on-prem and edge deployments, encrypts data in transit and at rest, and uses role-based access with audit trails for every action. You can integrate SSO/IdP (e.g., Okta/Azure AD), segment machine networks, and keep all production data inside the plant while still syncing selected analytics to the cloud if needed.
How does ForgeSense™ integrate with our existing MES/ERP, CAD/CAM, and CNC controllers?
The platform connects to controllers via OPC-UA/MTConnect, pulls geometry and programs from CAD/CAM, and exchanges orders and status with MES/ERP through REST APIs or file drops. Historians and sensors feed signals into the same data layer, so scheduling, simulation, QC, and reporting all work off a unified source of truth.