Solutions
Complete unmanned systems ecosystem from design through deployment. Vertically integrated capabilities delivering speed, security, and mission readiness.
The Complete UAS Ecosystem
Forge and Flight provides the only vertically integrated American UAS ecosystem—controlling aircraft design, electronics manufacturing, flight testing, and operator training under unified ownership.
Forge and Flight Labs
Aircraft Design & Manufacturing
Mission-specific NDAA-compliant platforms with advanced AI autonomy. Group 2 and 3 aircraft engineered from first principles for your operational requirements.
- Custom UAS design and engineering
- Advanced additive manufacturing
- AI integration (NVIDIA Orin/Thor)
- Rapid prototyping capability
Forge and Flight Avionics
NDAA-Compliant Electronics
100% domestically-sourced electronics manufacturing. Power distribution boards, avionics hubs, and custom PCB design with complete supply chain traceability.
- Aegis avionics series
- Domestic PCB fabrication
- IPC-A-610 Class 2/3 quality
- Zero foreign dependencies
Forge and Flight Test Systems
Test Range Operations
Dedicated test facilities with controlled airspace and professional range safety. Flight validation, mission rehearsal, and developmental testing services.
- 2,000-foot turf runway
- VTOL operations areas
- Range Safety Officer oversight
- Performance validation testing
Forge and Flight Academy
Operator Training & Certification
Platform-specific training programs, FAA Part 107 certification, capability assessment, and instructor development courses.
- Comprehensive operator training
- FAA Part 107 preparation
- Capability-based assessment
- Train-the-trainer programs
Why Vertical Integration Matters
End-to-end control delivers advantages impossible for fragmented competitors
Speed to Deployment
Traditional: 18-36 months
Forge and Flight: 3-6 months
Internal control eliminates multi-vendor coordination delays. Iterate in weeks, not quarters.
Supply Chain Security
Challenge: Foreign electronics create vulnerabilities
Solution: American UAS Electronics provides verified NDAA compliance
Complete documentation trail. Zero foreign dependencies.
Cost Efficiency
Traditional: Multiple vendor markups
Forge and Flight: Manufacturer-direct pricing
Internal electronics at transfer pricing. Cost advantages passed to customers.
Custom Engineering
Generic: Adapted commercial designs
Custom: Purpose-built for your mission
Direct engineer access. Rapid prototyping. Operational feedback integration.
Solutions by Customer Segment
Department of Defense
- Complete NDAA Section 848 compliance
- Blue UAS Framework certification path
- Rapid custom development for unique requirements
- Training programs tailored to unit operations tempo
Research Institutions & Universities
- Open software stack enables algorithm development
- Custom sensor integration for experimental payloads
- AI development platforms (NVIDIA Orin/Thor AGX)
- Comprehensive operator training included
Government Agencies
- DHS/FEMA grant-eligible systems
- State emergency management funding compatibility
- Net 30-60 payment terms for government POs
- Maintenance programs ensuring long-term readiness
Defense Contractors
- Electronics subsystems for proprietary platforms
- Custom avionics design and manufacturing
- Test range access for integration validation
- Volume pricing for production contracts
Technical Advantages
Advanced AI Autonomy
NVIDIA Thor AGX Integration: Production-grade edge computing enables closed-loop autonomous control. Real-time computer vision and decision-making without ground station dependency.
Unique Capability: Vanguard-14 and Titan-20 platforms dynamically modify missions based on onboard AI analysis—rare in sub-$1M systems.
Extended Endurance
Hybrid Propulsion: Gas-electric systems deliver 6-12 hour missions in Group 2 platforms, 7+ hours in Group 3.
Operational Impact: Persistent surveillance without battery limitations. Fewer flight cycles per mission area.
Heavy Payload Capacity
Titan-20 Flagship: 25kg payload capacity enables sophisticated ISR suites impossible on smaller platforms.
Mission Flexibility: Multiple sensors simultaneously. Heavy communication relays. Experimental equipment accommodation.
VTOL Operational Flexibility
No Runway Dependency: Vertical takeoff/landing eliminates infrastructure requirements. Deploy from remote locations, ships, or confined areas.
Fixed-Wing Efficiency: Transition to cruise flight maintains extended endurance while eliminating runway constraints.
Implementation Process
From discovery to deployment in 3-6 months
Discovery & Requirements
Mission specialists work with your team to define operational requirements, performance criteria, and integration constraints.
Solution Design
Engineers design optimal configuration balancing endurance, payload, autonomy, and budget. Multiple options with clear tradeoff analysis.
Manufacturing & Integration
Platforms manufactured in North Carolina. NDAA-compliant electronics integrated. Comprehensive quality testing throughout.
Flight Testing
Range-based testing validates performance. Mission profile rehearsal. Flight envelope expansion ensures safe operations.
Training & Deployment
Platform-specific operator training. Mission planning instruction. Maintenance procedures. Field support coordination.
Ongoing Support
Direct engineer access. Spare parts programs. Software updates. Annual maintenance. Upgrade paths as requirements evolve.
Ready to Discuss Your Mission Requirements?
Our specialists understand operational challenges across defense, research, and government sectors. We'll help you select the optimal platform configuration and integration approach for your specific needs.