Forming, Forging, and Stamping

Forming, forging, and stamping shape metal by plastic deformation, delivering high-strength, repeatable parts at production volumes with dedicated tooling and press capacity.

Overview

Forming, forging, and stamping are metalworking processes that reshape material without melting it, using dies, presses, and controlled deformation. Compared to cut-from-solid methods, they can reduce material waste and cycle time while improving grain flow and mechanical properties, especially in forged parts.

Choose this category when you need durable parts at medium to high volumes and your geometry fits die-based manufacturing. Tradeoffs center on tooling cost, lead time, and design constraints (draft, radii, parting lines, and access for trimming). Tolerances vary widely by process and typically require secondary machining for tight fits.

Common sub-processes include forging (open/closed-die for high strength), stamping (blanking, piercing, forming, progressive dies for sheet metal), extrusion (constant cross-sections with long lengths), and wire forming (springs, clips, frames).

Common Materials

  • Steel 4140
  • Stainless Steel 304
  • Aluminum 6061
  • Aluminum 6063
  • Brass C360
  • Titanium Ti-6Al-4V

Tolerances

±0.005" to ±0.020"

Applications

  • Automotive control arms
  • Hand tools and wrenches
  • Sheet metal electrical enclosures
  • Stamped brackets and clips
  • Aluminum heat sink extrusions
  • Coil springs and wire forms

When to Choose Forming, Forging, and Stamping

Target forming/forging/stamping when part demand justifies tooling and you need consistent cycle time, repeatability, and strong mechanical performance. It fits parts that can be designed around die constraints (radii, draft/relief, and trim features) and benefit from low material scrap at scale.

vs CNC machining

Choose forming/forging/stamping when volumes are high enough that tooling amortizes and you want lower piece price and faster cycle time. Forging in particular gives better strength-to-weight for many load-path parts than machining from bar with cut grain flow.

vs Metal casting

Choose forming/forging/stamping when fatigue strength, impact resistance, and ductility are critical and you want a wrought-like microstructure. These processes also avoid porosity risks that can drive inspection and scrap in some castings.

vs 3D printing (metal additive manufacturing)

Choose forming/forging/stamping when you need production throughput and consistent unit cost at volume. Die-based processes also deliver better surface finish and material properties without extensive post-processing on most commodity alloys.

vs Fabrication/weldments

Choose stamping/forming when you can consolidate multiple fabricated pieces into one formed part to reduce weld labor, distortion, and inspection. Progressive stamping and formed brackets can simplify assemblies and improve repeatability.

Design Considerations

  • Add generous radii and avoid sharp corners to reduce cracking, die wear, and tonnage requirements
  • Define critical datums and surfaces early and plan secondary machining only where needed for fits/seals
  • Keep sheet metal features compatible with forming rules (minimum hole-to-edge, bend radius, and bend relief) to prevent tearing and distortion
  • Design for trim and parting lines; locate them away from critical cosmetic or sealing surfaces when possible
  • Provide realistic tolerances by feature type (formed vs trimmed vs pierced); avoid blanket tight tolerances that force secondary ops
  • Include material spec, thickness/temper (for stamping), and target grain direction where performance depends on orientation