Established in 2007, USAI Forge Pvt Ltd (USAIFPL) is a leading manufacturer specializing in high-quality forgings and machined products for diverse industries, including Defence, Artillery & Ammunition, Oil & Gas, Automotive, Aerospace, and General Engineering.

Operating as a professionally managed Private Limited Company, USAI Forge is led by an experienced Board of Directors and skilled personnel across all operational areas. Our facility is equipped with advanced forging machines, induction heating systems, and fully automated material handling, ensuring precision and efficiency throughout the manufacturing process.

Our cutting-edge manufacturing infrastructure includes:

• Forging Facility: Induction Heating Systems, Hot Shear, 500 Ton Hydraulic Multi-function Press, 150 Ton Hammer with Manipulator, 2700 Ton Closed Die Screw Press, 500 Ton Hydraulic Extrusion and Piercing Press, 150 Ton Hydraulic Trimming Press, Automated Manipulators, Hydraulic Nosing Presses of 200 MT, 250 MT and 500 MT.
• Special purpose machines covering Knurling, Copper Banding Press, Dual Head Seam Welding.
• The facility is also equipped with Tum Blast, Shot Blasting, Phosphating, Zinc Surface Treatment, Custom Ovens, Painting, Engraving and Stamping equipment.
• Machining Facility: Vertical Turning Lathes, Horizontal Boring Machines, CNC & VMC Machines, Multi-Axis CNC Machines for machining of Forgings including the Bomb Shells and for machining of missile components and engineering parts.
• Composites Manufacturing Facility: With Composite materials taking a prominent role in the design and development of critical components used in various Industries, USAI Forge established a comprehensive facility for Composite Sections manufacturing including 4 Axis CNC Filament Winding machine, Creel Stand with 16 Spools, Autoclave, Rubber Mixing & Extruding Mill, Hot Feed Extruder, 500 Ton Hydraulic Rubber Moulding Press with Heating, 250 Ton Press, CNC Drum Winding Machine and other allied machines.

USAI Forge specializes in high-precision bomb shell production for the Artillery & Ammunition industry. Our facility is equipped to manufacture bomb shells in various sizes and types, including 51 mm, 60 mm, 81 mm, 105 mm, 120 mm, 122 mm, 130 mm, 152 mm, and 155 mm, adhering to stringent quality standards required by defence clients. Design and development of various sizes and variants of Bomb Shells as per the Customer requirements is part of the engineering and manufacturing activity at USAI Forge.

Our engineering department, backed by advanced software and experienced designers, develops and indigenizes a wide range of defence components, including:

• Missile Components: Invar Missile Components Tray & Shell, QRSAM, Titanium Propellant Tanks, B3 Nozzle Assembly, Bucket Flanges, Solid Propellant Mandrel Assembly, RVS Metallic Components, Nozzle End Dome, and Ceramic Radome machining.

USAI Forge also manufactures Oil Field Accessories to API Specifications 5CT/5DP/Spec 7-1, including Tool Joint Forgings for Drill Pipes, Subs, Crossovers, Lifting Bails, Couplings, and Pup Joints.

USAI Forge is committed to delivering precision-engineered forgings and machined components that exceed industry standards and customer expectations. Our Quality Management System, certified to ISO 9001:2015 and AS9100D, ensures rigorous quality control at every stage of production, earning recognition from prestigious companies and defence establishments.

We continuously enhance our processes, invest in cutting-edge manufacturing technologies, advanced testing methodologies, and adhere to stringent international standards to ensure zero-defect manufacturing. Our commitment to customer satisfaction, innovation, and sustainability drives us to remain a reputed manufacturer in defence, aerospace, oil & gas, automotive, and industrial engineering sectors.

Our facility houses a fully equipped Metrology & Metallurgical Laboratory for comprehensive material testing and product inspection including Ultrasonic testing, Wet Magnetic Particle inspection and hydrotesting.

USAI Forge is dedicated to environmental sustainability, actively preventing pollution and conserving resources through our “Going Green” initiative. We focus on developing and supplying indigenous products to Defence and industrial sectors.

USAI Forge is approved by numerous esteemed organizations worldwide, consistently delivering high-quality products that meet evolving industry demands. Our expertise in precision forging and machining, particularly in bomb shell manufacturing, sets us apart in today’s competitive landscape.

The global arms and ammunition market is witnessing significant growth, driven by escalating geopolitical tensions, prolonged military conflicts, defence stockpile pressures and a renewed focus on self-reliance. Governments worldwide are increasing defence expenditures to bolster their military capabilities, leading to a surge in demand for bomb shells and artillery components.

India is emerging as a global hub for artillery shell production, offering cost-effective, scalable, and export-ready solutions. The 155 mm shell market is projected to grow from $3.98 billion in 2023 to $6.99 billion by 2032 (CAGR 5.69%) and the total ammunition market is projected to grow from $28 billion in 2023 to $33.10 billion by 2028 (CAGR 3.40%).

USAI Forge is strategically positioned to supply the large calibre artillery shells, mainly 155 mm shells, with its state-of-the-art forging and machining capabilities. Our strengths in zero-defect manufacturing with rigorous quality assurance, cost effective production, export oriented production aligned with international standards and NATO specifications, international compliance, and scalable infrastructure to meet surge demands and long-term contracts makes us a trusted partner in strengthening regional and allied defence ecosystems.

We believe our facility and capabilities align with your requirements, and we look forward to the opportunity to collaborate with you.

For more information on our capabilities, please visit our website at www.usaiforge.com.

The corporate office is located in Hyderabad, Telangana, while the manufacturing facility is situated 90 kms away along National Highway 65 in Southern India. The nearest airport is Rajiv Gandhi International Airport, Hyderabad, offering convenient access for domestic and international connectivity.