AI FMEA Generator
Upload your design, spec, or test data. Get a complete FMEA with ranked failure modes, RPN scores, and specific corrective actions, in seconds. No spreadsheet, no manual scoring.
This is the capability ForgePilot was built around first, not a feature bolted onto a CAD add-in. Works from your uploaded files directly, whatever CAD system exported them.
Generate Your FMEA FreeNo credit card required · Free plan includes 10 analyses/day
No confusion, no setup
Exactly what happens, in order
Describe it or upload a file
Type your part or process in plain English, or upload a drawing, STEP file, or spec sheet. No template, no blank form to fill in first.
Get a ranked FMEA table
Every failure mode scored with Severity, Occurrence, Detection, and RPN, highest risk first, with a specific corrective action for each one, not generic advice.
Check it, then export
The reasoning and math are shown, not hidden, so you can verify before you trust it. Export as PDF when you're ready to attach it to a design review.
Real output, not a mockup
This is what you get back
From the prompt: "Run an FMEA on a rotating shaft assembly, 40mm diameter 4340 steel shaft, two SKF 6208 bearings, 200 N·m at 3000 RPM."
| Component | Failure Mode | S | O | D | RPN | Recommended Action |
|---|---|---|---|---|---|---|
| Shaft keyway fillet | Fatigue crack initiation | 9 | 5 | 7 | 315 | Increase fillet radius to r ≥ 1.5mm; shot peen keyway; Ra ≤ 0.8μm |
| Oil mist lubrication | Lubricant starvation | 9 | 4 | 6 | 216 | Add differential pressure switch; auto-shutdown at 2 min starvation |
| Bearing inner race | Spalling / fatigue pitting | 8 | 4 | 5 | 160 | Relubrication interval ≤ 500h; add ISO 10816 vibration monitoring |
Free, no sign-in
RPN calculator
Pick your Severity, Occurrence, and Detection ratings, get the Risk Priority Number instantly.
Severity (S)
Occurrence (O)
Detection (D)
RPN = S × O × D
7 × 4 × 5 = 140
General guidance
Medium priority
RPN 1-1000, done client-side, nothing sent anywhere. The High/Medium/Low band above is general reference, not the official AIAG-VDA Action Priority table, your org's FMEA procedure governs the real threshold. For ranked failure modes generated from your actual design, run it in the full workspace.
Full FMEA, freeWhat you get
Everything an FMEA needs
FMEA in under 2 seconds
Describe your design or upload a file: STL, STEP, PDF spec, CSV test data. ForgePilot returns a ranked FMEA table instantly.
Ranked failure modes with RPN
Every failure mode scored with Severity, Occurrence, and Detection ratings. Risk Priority Numbers calculated automatically, highest risk first.
Specific corrective actions
Not generic advice. Each failure mode gets a targeted recommended action: material change, geometry fix, process control, inspection step.
Multi-file cross-analysis
Upload up to 10 files at once. ForgePilot cross-references your CAD geometry, test logs, and spec sheets in a single FMEA pass.
Export to PDF or Markdown
One click exports your FMEA as a formatted engineering report. PDF or Markdown. Ready to attach to a design review package.
Iterate in the same session
Change a variable, add a constraint, upload a revision, ForgePilot updates the analysis in context without starting over.
FMEA for every engineering discipline
Whether you're doing DFMEA, PFMEA, or system-level FMEA, ForgePilot handles the analysis.
Automotive FMEA
DFMEA and PFMEA for powertrain, chassis, and safety-critical systems.
Aerospace FMEA
Failure mode ranking for flight-critical structures, avionics, and propulsion.
Medical Device FMEA
ISO 14971 risk analysis and FMEA for Class I, II, and III devices.
Manufacturing FMEA
Process FMEA for machining, welding, casting, and assembly lines.
Robotics FMEA
Actuator, sensor, and control system failure mode analysis.
Electronics FMEA
Component-level and board-level failure analysis for hardware design.
Frequently asked questions
Is the RPN calculator on this page free?
Yes. Pick your Severity, Occurrence, and Detection ratings and it computes RPN (S times O times D) instantly, entirely in your browser, no sign-in, no data sent anywhere. For AI-generated failure modes from your actual design, ranked and scored automatically, use the full workspace, also free to start.
What is an FMEA generator?
An FMEA generator is a tool that automates Failure Mode and Effects Analysis: identifying potential failure modes in a design, scoring their risk (Severity times Occurrence times Detection = RPN), and recommending corrective actions. ForgePilot does this from your design inputs without requiring you to fill in a template manually.
How is ForgePilot different from an FMEA Excel template?
Excel templates require you to identify every failure mode yourself and score them manually. ForgePilot identifies failure modes from your design, scores them with engineering reasoning, ranks by RPN, and outputs specific corrective actions, in seconds, not hours.
Does it support DFMEA and PFMEA?
Yes. ForgePilot handles both Design FMEA (DFMEA) focused on design-level failure modes and Process FMEA (PFMEA) focused on manufacturing and assembly process failures.
What file formats can I upload?
STL, STEP, IGES, DXF, PDF datasheets, CSV test logs, Excel (.xlsx) files including your existing FMEA templates, GCode, VTK simulation results, and Abaqus .inp files, up to 10 files per session.
What does RPN stand for in FMEA?
RPN stands for Risk Priority Number, the product of three 1-to-10 ratings: Severity (how bad the effect is), Occurrence (how likely the cause is), and Detection (how likely you are to catch it before it reaches the customer). RPN = S x O x D. Higher RPN means higher priority to fix. ForgePilot calculates it automatically for every failure mode it identifies, and the calculator above computes it instantly for a single failure mode you enter yourself.
What is considered a high RPN score?
There is no universal cutoff, RPN thresholds are usually set by your organization or program, and a max score of 1000 (10x10x10) is rare in practice. What matters more than the absolute number is the ranking: fix the highest-RPN failure modes first, and treat any failure mode with a Severity of 9 or 10 as a priority regardless of its overall RPN, since a catastrophic effect deserves attention even if it is rare or easy to detect.
Generate your first FMEA now
Free to start. No template, no spreadsheet. Upload a file or describe your design and get ranked failure modes in seconds.
Launch Workspace Free10 free analyses per day · No credit card required