Lightweight, high-strength aluminum forged parts designed for performance bicycles and electric bikes.
Offering superior fatigue resistance compared to die casting and lower overall cost than full CNC machining
Typical applications of aluminum alloy forging in bicycles
Thanks to the fatigue resistance and lightweight properties of forged aluminum alloy components
Mountain bike handlebar accessories
Road bicycle tubing
Brake calipers & mounts
BicycleStems & Handlebar Clamps
Bicycle pedal arms
Bicycle chainring and (6061 / 7075)
Why Aluminum Forging Is Ideal for Bicycle & E-Bike Components？
Bicycle manufacturers require lightweight, fatigue-resistant, and aesthetically pleasing anodized components
Advantages：
Lightweight Without Sacrificing Strength
Forged aluminum offers higher strength-to-weight ratio than CNC or casting.Perfect for Anodized Surface Finishing
No porosity, ensuring smooth and consistent anodized appearance.Designed for Dynamic Load & Fatigue
Ideal for pedaling forces, vibration, and long-term riding durability.
Forging sits between CNC machining and die casting, offering an optimal balance of strength, cost, and surface quality
Forging
Lightweight & Strong: Offers superior strength with reduced weight, ideal for automotive and industrial use.
No Porosity: Eliminates internal porosity for more reliable parts.
Cost-Effective: Reduces material waste with near-net shapes, cutting machining costs.
- CNC & Die Casting Benefits: Combines precision with cost-efficiency for a balanced solution.
High Precision: Provides exact tolerances for detailed parts.
Smooth Finish: Produces smooth surfaces, reducing finishing needs.
Low Initial Costs: No expensive tooling or molds, ideal for small batches
Cost-Effective for Mass Production: Low cost per part for high-volume runs.
High Yield: Produces high-quality parts with fewer defects.
Complex Shapes: Ideal for intricate designs with fine details.
Forging creates near-net-shape blanks, while CNC machining ensures tight tolerances and assembly accuracy
Benefits:
Reduced machining time
Lower material waste
Improved overall cost efficiency
Aluminum 6061
Aluminum 6063
Aluminum 6082
Aluminum 7075 (high-strength applications)
Hot forging of aluminum molds
Forging + CNC Machining Capability
Anodizing and surface treatment
Custom Tooling and Die Development
When Forging May Not Be the Right Choice
Parts Better Suited for CNC Machining
- Aluminum forging may not be ideal for parts that require extremely complex geometries, deep internal cavities, or frequent design changes.
- For low-volume production or highly customized components, CNC machining offers greater flexibility without tooling investment.
Limitations of Aluminum Forging
- While aluminum forging provides excellent strength and reliability, it does have certain limitations.
- Initial die development is required, making forging less economical for very small batch sizes or prototype-only projects.
Choosing the Right Manufacturing Process
- Forging, CNC machining, and die casting each serve different purposes.
Our engineering team evaluates your part design, volume requirements, and performance goals to recommend the most suitable manufacturing solution.
When Forging May Not Be the Best Choice？
Extremely low-volume prototypes
Very thin decorative parts
Very thin decorative parts
Looking for High-Performance Bicycle Forging Parts?
Send us your drawings or concepts, and our engineering team will help optimize your bicycle or e-bike components with aluminum forging
Q1. Is aluminum forging cheaper than CNC machining?
Answer:
For structural and high-volume parts, aluminum forging is often significantly more cost-effective than CNC machining. Forging creates near-net shapes, reducing machining time, material waste, and overall production cost while maintaining excellent strength and precision.
Q2. Can forged aluminum parts be anodized?
Answer:
Yes. Unlike die casting, aluminum forged parts have a dense, non-porous structure, making them ideal for anodizing. This allows for smooth surface finishes, consistent color, and high-quality appearance required for visible or premium components.
Q3. What types of parts are suitable for aluminum forging?
Answer:
Aluminum forging is ideal for load-bearing, structural, and safety-critical components such as automotive parts, motorcycle components, industrial brackets, and mechanical housings that require high strength, durability, and reliable surface quality.
Q4. Forging vs die casting: which process offers better strength?
Answer:
Forged aluminum parts offer significantly higher mechanical strength than die-cast parts. The continuous grain flow created during forging improves fatigue resistance, impact strength, and overall structural integrity.
Q5. Can forging replace CNC machining or die casting for my project?
Answer:
In many cases, yes. Aluminum forging often replaces full CNC machining or die casting when cost, strength, and surface quality need to be balanced. Forging combined with CNC finishing provides an optimal solution for performance and cost efficiency.
