COLD SPRAY COATING SERVICE BUSINESS PLAN

I. Executive Summary

Company Description

AeroForge Restoration — named to reflect aerospace focus and metal-forging precision — launches in 2026 in Wichita, Kansas. We operate in the industrial services sector, serving aerospace, defense, and energy customers with advanced metal restoration using cold spray technology. Our core offerings are precision repairs and additive manufacturing for mission-critical components, delivered from a facility with robotic deposition cells and an on-site metallurgical laboratory. A team of materials scientists and certified technicians executes repairs to extend component life and restore OEM-level performance. One-line: we return worn, cracked, and corroded parts to serviceable condition faster and with less thermal damage than fusion-based methods.

Primary activities include incoming inspection, metallurgical analysis, robotic cold spray deposition, post-process machining, qualification testing, and customer-certified documentation. We target MRO providers, OEM repair programs, and asset operators with high-value, low-volume parts that demand technical repair solutions. Short-term goals: secure three anchor contracts and complete AS9100-aligned process validation by Q4 2026. Long-term goals: scale to regional service hubs, add in-situ on-site repair teams, and achieve 30% gross margin on service work by year five. One-line: we compete on precision, metallurgical integrity, and documented flight/field readiness.

Problem

High-value metal components in aerospace, defense, and energy sectors experience wear, erosion, and localized damage that standard repair methods cannot fully fix. Welding and fusion-based repairs introduce intense heat that distorts parts, alters metallurgical properties, and reduces fatigue life, creating safety and performance risks.

Replacements cost tens to hundreds of thousands of dollars, carry lead times measured in weeks or months, and cause extended downtime that degrades operational readiness; supply-chain constraints and regulatory recertification amplify these delays and costs.

The market lacks a widely adopted, heat-free repair method capable of restoring complex geometries to original specifications without thermal degradation, leaving operators to choose between weakened repairs or costly replacements. One clear need: a scalable, certified, heat-free restoration service that returns components to service quickly and without metallurgical damage.

Solution

Critical aerospace and defense components suffer wear and damage that heat-based repairs like welding can worsen through thermal distortion and metallurgical change, forcing costly replacements and long downtime. We restore and rebuild flight-critical parts using precision cold spray additive repair that deposits metal supersonically without high temperatures, returning components to original specifications with superior material properties and minimal risk of heat-induced damage. We also deliver comprehensive quality assurance, non-destructive testing, and metallurgical analysis for flight-critical safety.

High-fidelity, low-heat metal restoration for flight-critical parts.

Mission Statement

We revolutionize industrial component lifecycle management by delivering the most advanced, heat-free metal repair and manufacturing solutions that extend asset life and improve operational safety. We commit to material-science-driven innovation and technical excellence to be the trusted partner for aerospace and defense customers, delivering measurable reliability and value in every micron of metal we deposit. We reduce industrial waste and cost by making otherwise impossible repairs possible, protecting mission-critical assets and the people who rely on them.

Key Success Factors

Success depends on technical excellence, certified processes, strategic location, customer relationships, and disciplined operations.

• Specialized cold spray technology and a team of materials scientists and certified technicians.
• AS9100 and FAA certifications required for aerospace and defense contracting.
• Location in a major manufacturing hub enabling efficient logistics and skilled labor access.
• Long-term service agreements secured via strong OEM and defense contractor relationships.
• Operational discipline driving Year 5 EBITDA of $4,980,000 as the primary financial target.

Financial Summary

Financial snapshot for the Executive Summary: the plan projects rapid revenue and EBITDA growth with early breakeven and full payback within 25 months.

Funding need and returns: maintain a minimum cash balance of $314,000 (min cash month Jul-26); operational breakeven expected Feb-2026; total payback in 25 months; investors should expect IRR 6.46% and ROE 12.6% over the five-year plan.

Outlook: strong margin expansion and positive cash flow support a stable, investable business through 2030.

Funding Requirements

We require $1,240,000 of initial funding to purchase equipment, complete facility buildout, and fund early operations to reach our 2030 revenue target.

Financial snapshot: Year 1 revenue $2,130,000 growing to $8,918,000 by 2030; operational breakeven by February 2026; 25 months to full payback; EBITDA from $485,000 (Year 1) to $4,980,000 (Year 5); IRR 6.46%; ROE 12.6%; maintain minimum cash balance $314,000.