Complex parts call for a new approach: Forge Motorsport relies on hyperMILL®
11.11.2026 — As its range of performance parts grew and components became increasingly complex, Forge Motorsport & Engineering realized that its machining capabilities had to evolve as well. The move towards 5-axis machining was an important step. But getting the most out of the new technology also required the right CAM solution. With hyperMILL®, the company has created an efficient and reliable process for manufacturing demanding components while keeping cycle times and lead times under control.
Based in Gloucester, UK, Forge Motorsport & Engineering manufactures performance products and aftermarket parts for petrol and turbo vehicles, supplying customers around the world. As its product portfolio grew, so did the demands on its manufacturing operations. In 2019, the company decided to invest in its CNC capabilities, including 5-axis machining, and began looking for CAM software that could support this development.
Confidence before the machine starts
For Forge Motorsport, efficient machining starts long before the cutting tool reaches the component. Its engineers need to program complex parts accurately and efficiently, while having confidence that the program will run as intended at the machine. Reliable simulation, accurate 5-axis toolpaths and efficient programming were therefore key requirements.
With hyperMILL®, offline programming, simulation and machining form a connected process that helps Forge Motorsport make efficient use of its 5-axis equipment. The hyperMILL experts also helped the team resolve programming challenges quickly and build its own expertise.
Ryan Speck, Chief Engineer at Forge Motorsport & Engineering, explains the impact: “hyperMILL® has given us the ability to increase our efficiency by reducing our cycle times and enabling us to program offline. This has made us more competitive within the subcontract engineering industry.”
Complex parts, efficient machining
The benefits can be seen in components such as the DV37 dump valve. Forge Motorsport uses hyperMILL® MAXX Machining and trochoidal toolpaths to achieve high material removal rates and short production times, even in areas that would be difficult to machine using conventional strategies.
The company can also respond more efficiently to design changes. With the merge function in hyperMILL®, programmers can update an existing model and adapt the relevant machining operations instead of starting the programming process again.
For Forge Motorsport, the result is greater efficiency and confidence when manufacturing complex parts. Shorter cycle times and offline programming help the company meet deadlines, keep lead times under control and remain competitive in a demanding market.
Discover how Forge Motorsport & Engineering uses hyperMILL for complex 5-axis machining.
