Automotive Additive Manufacturing + Finishing

South DFW — Waxahachie, TX

Parts That Fit. Finished to Last.

Forge 77 is a scan-to-finished-part operation for automotive restoration, motorsport, and restomod builds. We prototype fast, validate fitment on the actual vehicle, and produce in engineering-grade materials — then finish in-house with vapor honing, Cerakote, and media blasting.

Request a Quote See the Process

Application

Classic Restoration

Reproduce discontinued parts from a sample, scan, or drawing. NLA brackets, trim, housings, and hardware — in polymer or cast metal.

Application

Motorsport

Brake cooling ducts, aero components, sensor mounts, and quick-turn prototypes for track builds. PA12-CF for heat and strength where it matters.

Application

Restomod

Custom brackets, mounts, adapters, and ducts for modern swaps. Designed around packaging constraints and clean installs — made to fit the build.

Application

Finishing & Refinishing

Vapor honing, Cerakote, and media blasting for printed parts, cast parts, and existing components. Available standalone — no AM purchase required.

3D scanning an automotive part

Fitment Lab

Prototype First.
Produce When It's Right.

Most shops scan a part and go straight to production. We don't. The Fitment Lab starts with 3D scanning and reverse engineering — then moves through rapid prototyping and physical fitment validation before a single production part is made. That sequence is what keeps rework off the table.

01

Scan & Reverse Engineer

No drawings? No problem. We 3D scan sample parts, worn components, or mounting surfaces to capture exact geometry. From the scan we build a clean CAD model — the foundation everything else is built on.

02

Scope the Problem

Function, environment, tolerances, and success criteria locked in before a single layer is printed. If you have STL/STEP files already, we start here.

03

Rapid Prototype

We print fast — not in the final material, but accurate enough to test. Geometry is confirmed, interference points are identified, and install clearances are checked on the actual vehicle or assembly.

04

Iterate Until Right

If something needs to change, we change it and print again. Revisions are fast and cheap at this stage — not after 20 production parts are sitting on your bench with the wrong hole spacing.

05

Approve, Then Produce

Once fitment is signed off, we hand the validated design to production. Engineering-grade materials, correct quantity, finishing included if specified.

Why It Matters for Shops

Restoration and restomod work runs on reputation. A part that doesn't fit the first time costs you time, materials, and trust with the customer. The Fitment Lab exists to eliminate that risk before production.

Send us a part, a photo, measurements, or a scan file. We'll produce a prototype, verify fitment, and give you a production-ready design with documented revisions before you commit to quantity.

  • 3D scanning from sample parts, worn components, or mounting surfaces
  • Prototype prints included in project scope
  • On-vehicle fitment verification before final production
  • Revision cycles tracked and documented
  • No surprise rework charges post-production
Forge 77 production printer

Production - Additive Manufacturing

Engineering-Grade Materials.
Production-Ready Parts.

Once design and fitment are validated through the Fitment Lab, production runs in the right material for the application. We're not a general-purpose FDM shop — every material in our stack was selected for automotive and industrial environments where heat, vibration, and chemical exposure are real.

Material Stack

PA12-CF (Nylon 12 Carbon Fiber) Primary

Primary production material for structural automotive parts. High stiffness, excellent heat resistance, low moisture absorption. Validated in racing applications — used by NASCAR Cup teams. Best for brackets, ducts, mounts, and housings in heat-adjacent environments.

ASA (Acrylic Styrene Acrylonitrile) Production

UV-stable, weather-resistant exterior parts. Replaces ABS for parts exposed to the elements — exterior trim, underhood cosmetics, and any part that will see sunlight or temperature swings without a painted finish.

ABS / PA6 / TPU Application-Specific

ABS for period-correct interior reproduction and cosmetic parts. PA6 (glass-filled) for high-load structural components. TPU for seals, grommets, bumpers, and vibration isolators where flexibility is required.

Castable Resin → Metal Casting Workflow

For parts requiring metal — badges, brackets, small housings — we print precision resin masters and outsource to investment casting partners for aluminum, brass, or bronze output. Eliminates tooling costs for small runs.

Capabilities

  • Build Volume Up to 320 × 320 × 320 mm standard; multi-part nesting for small runs
  • Tolerances ±0.2 mm typical; tighter tolerances available depending on material and geometry
  • Run Size One-off prototypes through small production runs (1–50 units typical)
  • File Formats STL, STEP, IGES, native CAD files accepted; we can work from sketches or sample parts
  • Post-Processing Support removal, surface prep, priming, and handoff to Cerakote or painting as required
  • Not Available Safety-critical structural components (suspension links, brake calipers, steering)

Investment Casting for Metal Parts

When polymer isn't the right answer — badges, show-quality hardware, material-correct reproductions — we produce precision resin masters in-house and coordinate with local investment casting partners for aluminum, brass, or bronze output. No tooling investment required for small runs. Typical lead time: 2–4 weeks from approved design.

Vapor honing cabinet

Finishing Services

The Right Surface.
Not Just "Done."

We operate vapor honing, Cerakote coating, and media blasting in-house. These are standalone services — you don't need an AM job to use them. Restoration shops and engine builders use us for finishing on their own castings, heads, and hardware. The combination of all three in one shop is effectively unavailable elsewhere in South DFW.

Vapor Honing

Wet abrasive blasting with slurry media — delivers a clean, satin finish on aluminum, cast iron, and steel without the surface stress of dry blasting. Ideal for carburetors, intake manifolds, valve covers, heads, crankcases, and show-quality engine hardware.

Aluminum Cast Iron Steel Carbs & Manifolds Cylinder Heads Valve Covers

Cerakote Coating

Polymer-ceramic coating for extreme heat resistance, corrosion protection, and a durable matte or satin finish. We apply automotive and industrial Cerakote — headers, exhaust manifolds, intake components, engine bay hardware, and printed parts requiring UV and chemical resistance.

Headers & Exhaust Intake Components Engine Bay Hardware Printed Parts Corrosion Protection

Media Blasting

Dry media blasting for aggressive prep, rust removal, and paint stripping. Used as a surface prep stage before vapor honing or Cerakote, or as a standalone service for parts that need scale and oxidation removed before machining or welding.

Rust Removal Paint Stripping Surface Prep Pre-Cerakote Pre-Weld Cleanup

Finishing-only jobs are welcome. We work with restoration shops, engine builders, motorcycle shops, and individual enthusiasts who have their own parts and just need a finishing service. No 3D printing required. Common bundled workflow: media blast → vapor hone → Cerakote — available as a single job with one drop-off.

Magnaflux inspection wand on automotive part

QC & Inspection

Every Part Checked.
Not Just Shipped.

QC is built into every job — not optional, not an add-on. For shops that need documentation, we provide inspection reports. For individuals who want us to evaluate an existing part, we offer dimensional inspection and condition assessments.

For Shops & Production Jobs

  • Dimensional Verification Critical dimensions checked against approved design file before parts leave. First-article inspection available for repeat production jobs.
  • Fitment Sign-Off Prototype fitment documented before production is approved. Revision history maintained. No surprises after full-quantity runs.
  • Surface Finish Inspection Finished parts inspected for coverage, adhesion, and surface quality before shipment. Cerakote and vapor-honed parts evaluated against job spec.
  • Production Inspection Reports Available for B2B accounts — basic documentation of quantities, dimensions checked, and pass/fail status. Useful for shops that document vendor QC.

For Individual Part Evaluation

  • Dimensional Inspection Send or bring a part and we measure it. Useful for determining if a used part is in spec, identifying wear, or validating a reproduction before installation.
  • Condition Assessment Visual and dimensional evaluation of existing parts — corrosion extent, structural integrity, print layer adhesion, surface defects. Good for used parts before you invest in finishing work.
  • Fitment Verification If you have a reproduction part and want to confirm it fits before installation, bring it and the reference hardware. We check it against spec or sample.
  • Scan & Document 3D scan of an existing part to create a dimensional record, capture wear, or establish a baseline for reproduction. Scan file delivered with inspection.

About Us

Forge 77

Forge 77 founders at a motorsport event

Forge 77 is an additive manufacturing and finishing shop built for automotive work — restoration, motorsport, and restomod builds where getting the part right actually matters. We're based in Waxahachie, Texas.

We built this shop around a simple idea: do the work honestly. That means telling you when a material won't hold up, when a design needs another iteration, or when a different process would serve you better. It means prototyping before producing, checking every part before it leaves, and not cutting corners on finish because it's faster. The work either meets the standard or it doesn't ship.

Most shops that print don't finish. Most shops that finish don't print. We do both in-house — vapor honing, Cerakote, media blasting — which means one workflow, one point of contact, and no handoff gaps between the part coming off the printer and the part going on the car.

We're not the biggest shop. We're not trying to be. We're trying to be the one you trust to get it right.

Send It!
Miles Sims & the Forge 77 Team

Location Waxahachie, TX — South DFW
Focus Automotive restoration, motorsport, restomod
AM Materials PA12-CF, ASA, ABS, PA6-GF, TPU, castable resin
Finishing Vapor honing, Cerakote, media blasting
Run Size One-off through small batch (1–50 units)
File Formats STL, STEP, IGES, native CAD, sketches
Contact [email protected]

Have a part that needs to be right the first time?

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