This paper describes a FEM-based computer system implemented by BethForge to model the open-Die forging process and its application to product and process development. A brief overview of BethForge, the markets it serves, and the typical product development cycle is given. Alternative methods for modeling open-Die forging are discussed and the advantages offered by FEM techniques due to recent advances in computer hardware and software are presented. The FEM-based modeling system that BethForge has developed in partnership with the Lehigh University Computer Integrated Manufacturing Laboratory (LU-CIM) and UES, Inc. is described along with the associated modeling methodologies. Several case studies are presented including 2D-axisymmetric simulation of head-forming, punch-forming, upsetting, and back extrusion, and the 3D simulation of ingot cogging.