Fast-Turnaround Prototype Forgings for R&D, PPAP & New Product Development
Shivam Forge manufactures prototype and trial forgings — 3 to 50-piece sample runs — with die manufacture in 2–3 weeks and first articles in 3–4 weeks from drawing approval. We support R&D teams, automotive PPAP submissions and industrial product development with full FAIR documentation, CMM dimensional reports, 3D scanning and material certifications at our Shapar GIDC facility in Rajkot, Gujarat.
Most forging manufacturers are set up for production runs of 1,000 pieces and above. Prototype and trial run customers get slower service, less documentation and toolmakers who are not incentivised to prioritise small orders. Shivam Forge has built a dedicated prototype forging process: DFM review of your drawing, die design and manufacture within 2–3 weeks, first article forgings with a full First Article Inspection Report, CMM dimensional report and material certification. For R&D teams and PPAP engineers who need documented first articles fast, we are the right supplier.
Before die cutting starts, our applications engineer reviews your drawing for Design for Manufacturability. We check draft angles, fillet radii, parting line position, flash allowance and material flow path. DFM comments are issued within 48 hours. After DFM sign-off, die design is completed and released for machining.
Prototype dies are machined from H13 hot work tool steel on CNC machining centres with EDM finishing for complex cavities. Die cavity dimensions are verified by 3D scanning against the die design model before first forging trial. Die manufacture lead time is 2–3 weeks from DFM-approved drawing.
The first forging trial (5–10 pieces) is used to set the correct billet weight, furnace temperature, press load and die lubrication. Die fill and flash distribution are checked. Any under-fill or die flow defects are corrected by die reworking before first article forgings are produced.
First article forgings are measured on our 3-axis CMM against all drawing dimensions. The FAIR includes: all critical and major dimensions with actual vs. nominal values, surface condition notes, material certification cross-reference and heat treatment record. FAIR is issued in 5 working days from first article forging.
For complex geometries, first articles are 3D scanned and the scan data overlaid on the customer's CAD model to produce a colour deviation map. This shows both dimensional deviation and surface quality across the entire forging surface — far more informative than a coordinate point report alone.
Once the prototype is approved, we hold the die in our toolroom and transition to production quantities without any additional die cost. Production process parameters (billet weight, furnace setpoint, press stroke, die lube) documented during prototype are used for production, ensuring first-off-tool consistency.
We accept drawings in STEP, IGES, SolidWorks (.sldprt, .sldasm), CATIA V5 (CATpart), ProE/Creo (.prt) and PDF 2D drawings. 3D native CAD files are preferred for die design — they eliminate re-drawing errors and allow direct import into our CAM system for die machining.
Every prototype forging batch is accompanied by a full material test certificate: steel mill heat analysis (C, Si, Mn, P, S, Cr, Mo, Ni, V as applicable), in-house spectrometric verification, and heat treatment record. Material traceability from mill certificate to finished forging is maintained even on 3-piece prototype runs.
We apply the same heat treatment on prototype forgings as on production pieces. Quench and temper, normalise, solution anneal — whichever is specified. Prototype heat treatment records (temperature charts, hardness test results) are included in the FAIR documentation package.
We sign Non-Disclosure Agreements for all prototype development projects as standard. Your drawing, design intent and application remain confidential. NDA is signed by our director before DFM review begins — we do not start technical discussions before NDA execution if requested.
PPAP Level 3 submissions for automotive OEMs require FAIR, material certification, process control plan, PFMEA and MSA. We can produce all manufacturing documentation required for Level 3 PPAP submission alongside the prototype forgings. PPAP documentation is completed in parallel with first article inspection.
Prototype orders at Shivam Forge go through the same DFM → die design → die manufacture → first article → FAIR process as our production programs. Prototype dies are tracked on the same toolroom schedule as production dies. First articles are inspected on the same CMM. You get production-quality documentation from a 10-piece prototype run.
Carbon steel (SAE 1040, SAE 1045), alloy steel (EN19, EN24, SAE 4140, SAE 4340), stainless steel (SS316, 17-4PH, duplex 2205), tool steel (H13, D2) and special alloys — we can source and forge prototype quantities of any grade with certified material. Minimum billet order from our steel stockholders is typically 100–200 kg.
We provide a single technical point of contact for each prototype project. DFM comments are specific and actionable — not generic. Drawing mark-ups are returned with comments in 48 hours. Progress updates are provided at each milestone (die design sign-off, die manufacture complete, first trial, FAIR complete) without the customer needing to chase.
Even 3-piece prototype runs go through our ISO 9001:2015 documented system. Job card, material traceability, heat treatment record, inspection record and FAIR are generated for every prototype order. This means the quality documentation trail starts with the first piece, not at production release.
Prototype forging in Europe or North America carries significant die cost (€5,000–15,000 for a small die) plus high piece price at low quantities. Shivam Forge's die costs for small prototype dies are typically ₹50,000–2,00,000 ($600–$2,400), with prototype piece prices typically 2–5× production piece price — not 10–20× as quoted by some European forging houses.
With 500+ OEM clients across automotive, oil & gas, agricultural and industrial sectors, Shivam Forge has processed hundreds of first article approvals. We know what PPAP Level 3 requires, what an FAI under AS9102 needs, and what a European automotive OEM supplier quality engineer will ask for at drawing approval. We build the right documents the first time.
Shivam Forge is a prototype forging manufacturer at Shapar GIDC, Rajkot, Gujarat, providing fast-turnaround sample and trial forging services for automotive R&D teams, industrial product developers, PPAP engineers and export customers. We manufacture prototype runs of 3–50 pieces in all steel grades — carbon steel, alloy steel, stainless steel and special alloys — with die manufacture in 2–3 weeks and full First Article Inspection Report (FAIR) plus CMM dimensional report delivered with the first article parts. Our ISO 9001:2015 quality system applies from the first prototype piece, providing full material traceability and heat treatment documentation from day one.
The prototype forging process at Shivam Forge starts with a DFM (Design for Manufacturability) review of your drawing or 3D model within 48 hours of submission. Our applications engineer checks draft angles (minimum 5° on external faces for steel forgings, 7° on internal faces), fillet radii (minimum 3 mm on external radii to avoid die wash), parting line position and billet weight estimate. DFM comments are returned as a marked-up drawing with specific numeric recommendations — not generic guidance. After DFM approval, die design is completed and die machining begins on our CNC machining centres using H13 hot work tool steel.
First article forgings are inspected on our 3-axis CMM (measuring volume 700×500×500 mm) against all drawing dimensions. The FAIR covers all critical and major dimensions with actual vs. nominal values, with a pass/fail determination per the drawing tolerances. For complex forgings, we additionally 3D scan the first article and generate a colour deviation map overlaid on the customer's CAD model — this shows in one image how close every point on the forging surface is to the design intent, rather than just the coordinate points selected for CMM measurement.
For automotive PPAP submissions, we produce Level 3 documentation in parallel with prototype production. This includes the FAIR, material test certificate, heat treatment record, process control plan, PFMEA (Process Failure Mode Effects Analysis) and MSA (Measurement System Analysis) for critical dimensions. PPAP documentation is completed and available for submission to the customer's SQE (Supplier Quality Engineer) within 5 working days of first article approval. We have processed PPAP Level 3 submissions for Indian and European automotive OEMs and understand the documentation format expected.
Prototype forging pricing from Shivam Forge is structured to make short runs economically viable. Die costs for small parts (0.5–5 kg) are typically ₹50,000–1,50,000 — far below European die costs at the same part size. Piece price for 10-piece prototype runs is 2–5× production piece price, reflecting the per-piece contribution to die cost and the higher per-piece setup cost at low quantity. Once a prototype is approved and production quantities are confirmed, the die cost is amortised and piece price drops to production pricing. Contact us at +91 92657 72827 or email sales@shivamforge.com with your drawing to start your prototype forging project.
Total prototype delivery time is 3–4 weeks from DFM-approved drawing: die manufacture takes 2–3 weeks, first article forging and FAIR takes 1 week. Complex dies with deep cavities or multi-impression layouts may require 4 weeks for die manufacture. We confirm the exact schedule with your project timeline before starting.
Minimum prototype run is 3 pieces, which is sufficient for FAIR inspection, material destructive testing (tensile, hardness) and customer evaluation. We recommend 5–10 pieces for the first article run to have enough pieces for full inspection plus spares for customer testing. For PPAP Level 3, we recommend 25 pieces.
Standard prototype documentation includes: First Article Inspection Report (FAIR) with all drawing dimensions measured, 3D scan colour deviation map (for complex parts), material test certificate (mill heat analysis + spectrometric verification), heat treatment record, and hardness test report. PPAP Level 3 documentation (control plan, PFMEA, MSA) is available on request.
We accept STEP, IGES, SolidWorks (.sldprt), CATIA V5 (CATpart), ProE/Creo (.prt) and PDF 2D drawings. STEP or IGES 3D files are preferred for die design. If you only have a PDF drawing, our CAD team will create a 3D model for die design — just allow an additional 2–3 days.
Die cost for a small prototype forging (part weight 0.5–5 kg, one impression) is typically ₹50,000–1,50,000 ($600–$1,800) depending on part complexity. Large complex parts (5–50 kg, multi-impression) may be ₹1,50,000–4,00,000. Die cost is quoted separately and amortised over the agreed production quantity once prototype is approved.
Yes. We can forge prototype quantities of duplex 2205, super duplex 2507, SS316L, 17-4PH, nickel alloy 625 and other special alloys. Minimum billet sourcing for special alloys is typically 50–100 kg — we advise on the minimum order when you send the drawing. Material certification is provided for all prototype special alloy forgings.
Yes. We sign Non-Disclosure Agreements before DFM review begins on all prototype projects where the customer requests it. Our NDA covers drawing confidentiality, application information and commercial terms. NDA is signed by our director and returned within 24 hours.
Email your drawing (STEP, IGES or PDF) with material grade, heat treatment specification and required quantity to sales@shivamforge.com. If NDA is required, request it in the same email. We will respond within 24 hours with a DFM review appointment and quotation covering die cost and piece price. Call +91 92657 72827 for urgent prototype requirements.
Why Choose Shivam Forge
Shivam Forge delivers precision hot-forged components from our integrated Shapar, Rajkot facility — covering forging, CNC machining, heat treatment, and quality inspection under one roof.
