Complex aluminum forgings for defense applications

The requirements in defense technology are clearly defined—but technologically demanding: components must be lightweight, robust, dimensionally stable, and resistant to environmental stresses. This applies in particular to load-bearing or protective components such as housings, structural connections, or shafts.

Aluminum is the material of choice for these requirements—especially when it is not cast or milled, but rather processed using forging techniques.

KAISER Aluminium-Umformtechnik supports OEMs and system providers with custom-made forged parts, which are created based on design drawings or in co-engineering. Series products or catalog components are generally not offered—with the exception of a predefined AR-15 housing part, which was developed specifically for smaller manufacturers.

Aluminum in military applications – why the material is so impressive

Aluminum offers a combination of advantages that are indispensable in tactically demanding applications:

• Low weight with high stability
• Resistance to corrosion, moisture, and temperature fluctuations
• Non-magnetic – no interference with sensitive electronics
• Dimensionally stable and resilient under structural stress
• Easy to process and refine (e.g., anodized, coated)

The drop forging process also gives the material a directional grain structure, which significantly increases its mechanical strength and fatigue resistance—a clear advantage over cast or milled parts.

No standard solutions – only manufacturing on demand

KAISER manufactures forged parts for defense technology exclusively based on customer drawings or accompanies the development process through technical co-engineering. The focus is on components with high demands on:

• Accuracy of fit and tolerance control
  

• Stress resistance (e.g., shock, torsion, vibration)
  

• Integrated mounting points or interfaces
  

• Finishing options for increased environmental resistance
  

Typical examples are:

• Housing for critical components
• Interface elements, such as connectors

AR-15 housing part – our only proprietary solution

With the AR-15 upper and lower receiver, KAISER offers a pre-engineered forging solution that has been made available specifically for smaller OEMs or manufacturers. These components are the only standard model in the portfolio—everything else is manufactured exclusively to order.

Features of the AR-15 housing:

• Drop-forged aluminum blank
• High dimensional accuracy & strength
• Optional CNC machining & anodizing
• Reproducible even in medium series quantities
• No minimum order quantity

This enables KAISER to provide customers with limited investment capacities access to high-quality forging technology.

Vertical integration & quality assurance

KAISER offers deeply integrated manufacturing tailored to demanding industries such as defense technology:

• Drop forging with controlled fiber flow
  

• precise CNC finishing
  

• Surface finishing according to technical specifications
  

• Marking, serial numbers, and documentation upon request
  

Quality assurance is carried out on a project-specific basis – including acceptance tests, test reports, and series approvals upon request.

Conclusion: Aluminum forgings for systems with responsibility

Defense systems require reliable components – in terms of function, design, and materials.

KAISER Aluminium-Umformtechnik does not supply off-the-shelf components, but develops and manufactures customized solutions – forged part by forged part.