“Precision for Defence, Reliability for the World”
“Strategic Manufacturer of Bomb Shells”
‘Precision, Reliability, Excellence’

Usai Forge is a trusted manufacturer of high-precision artillery bomb shells ranging from 51 mm to 155 mm, including advanced Bourrelet and ERFB variants. With proven supply records to Indian defence establishments and global procurement networks, the company delivers scalable production aligned with global standards.

Strategically positioned to meet rising demand, Usai Forge combines state-of-the-art forging and CNC machining infrastructure with ISO 9001:2015 and AS9100D certified quality systems. The FY 2026–27 expansion ensures surge readiness, long-term defence contracts, and sustained contribution to global competitiveness.

Company Overview

Usai Forge Pvt Ltd, established in 2007 and headquartered in Hyderabad, India, is a professionally managed, privately held company with a modern manufacturing facility located 90 km away on National Highway 65. Spread across six acres with 100,000 square feet of covered area, the facility is strategically connected to highways, ports, and the Rajiv Gandhi International Airport, ensuring seamless domestic and international access.

Guided by an experienced Board of Directors and supported by skilled personnel, Usai Forge has built a strong reputation in precision forgings and machined products for defence, artillery and ammunition, aerospace, oil and gas, automotive, and general engineering sectors.

Defence Manufacturing Expertise

At the core of Usai Forge's capabilities lies its role as a strategic manufacturer of high-precision bomb shells ranging from 51 mm to 155 mm, including advanced Bourrelet and ERFB variants. Configurations cover High Explosive (HE), Smoke, Illumination, DPICM, and ERFB shells, all manufactured to stringent defence quality standards.

Usai Forge's facility is equipped to produce a comprehensive range of calibres — 51 mm, 60 mm, 81 mm, 105 mm, 120 mm, 122 mm, 130 mm, 152 mm, and 155 mm — meeting diverse artillery and ammunition requirements. The engineering department undertakes the design and development of multiple sizes and variants, tailored to customer specifications, reinforcing flexibility and responsiveness in defence manufacturing.

The FY 2026–27 expansion plan includes commissioning a new forging line and an automated CNC machining facility, significantly enhancing production capacity and ensuring readiness for long-term defence contracts. This expansion strengthens Usai Forge's ability to meet surge demands while maintaining compliance with international defence procurement pipelines.

Facilities and Capabilities

• Forging Facility: Equipped with induction heating systems, hydraulic multi-function presses, screw presses, extrusion and piercing presses, trimming presses, hammers with manipulators, and specialized nosing presses.
• Machining Facility: The machining facility is equipped with advanced CNC machines integrated into an automated CNC machining line. Operations are supported by robotic tending systems, ensuring precision, efficiency, and continuous production across diverse machining requirements.
  
  In addition to CNC machining, the facility houses specialized equipment dedicated to knurling, copper banding, and seam welding. These specialized machines complement the CNC line by enabling tailored processes that meet specific product and customer requirements.

• Finishing & Surface Treatment: In-house blasting, phosphating, painting, engraving, and stamping.
• Metrology & Metallurgical Laboratory: Dimensional inspection, mechanical testing, ultrasonic and magnetic particle inspection, hydrotesting, and spectrometry, validated by NABL-accredited laboratories.

Quality & Certifications

Usai Forge operates a Quality Management System certified to ISO 9001:2015 and AS9100D (EN 9100:2018). Continuous re-certification since 2007 demonstrates sustained compliance, strict adherence to international standards, and a commitment to customer satisfaction.

Strategic Positioning of Usai Forge in Artillery Shells

The global arms and ammunition market is expanding rapidly, driven by escalating geopolitical tensions, prolonged military conflicts, defence stockpile replenishment, and a renewed emphasis on self-reliance. Governments worldwide are increasing defence expenditures to strengthen military capabilities, resulting in sustained demand for artillery shells.

Market Projections (Starting 2026)

• 155 mm Shell Market: USD 3.58 billion in 2026 → USD 9.01 billion by 2034 (CAGR 12.20%).
• 105–155 mm Artillery Shells: USD 5.61 billion in 2026 → USD 8.74 billion by 2034 (CAGR 5.81%).
• Global Ammunition Market: USD 34.81 billion in 2026 → USD 66.06 billion by 2031 (CAGR 13.70%).

Usai Forge is strategically aligned to capitalize on this rising global demand through:

• Export-ready infrastructure: Scalable production capacity designed for surge demands and long-term contracts.
• Cost-effective production: Competitive manufacturing efficiencies ensuring affordability without compromising quality.
• Compliance: Production aligned with international defence standards for seamless integration into allied defence ecosystems.
• Forging & machining expertise: State-of-the-art facilities with rigorous quality assurance and metrology.
• Trusted partner status: Proven reliability in strengthening both domestic and allied defence supply chains.

Other Products

Beyond bomb shells, Usai Forge manufactures forgings and machined components for artillery and tactical missile systems, aerospace assemblies, and specialized oil field accessories to API specifications. These include Tool Joint Forgings for Drill Pipes, Subs, Crossovers, Lifting Bails, Couplings, and Pup Joints.

The engineering department has successfully indigenized critical defence and aerospace components, reinforcing self-reliance and competitiveness.

Sustainability

Usai Forge emphasizes pollution prevention, resource conservation, and ethical manufacturing practices as integral to its operations. With proven capabilities, export-ready infrastructure, and rigorous quality assurance aligned with international standards, the company delivers cost-effective production through scalable infrastructure.

Dedicated to innovation, customer satisfaction, and sustained contribution to defence self-reliance and global supply chains, Usai Forge stands as a reputed manufacturer with certified processes and a commitment to environmental sustainability embedded in its practices.