SOLUTION · COST AT VOLUME
Machining from solid?
See what forging
does to your unit cost.
Send the same drawing you send your CNC shop. We review whether a forged blank plus finish machining cuts your cost — and tell you honestly when it doesn’t.
THE PROBLEM WE SOLVE
Why parts machined from solid get expensive
Material you never use
Block machining turns 50–80% of premium aluminium into chips you paid for.
Hours on the spindle
Every removed cubic centimetre is machine time — the cost scales with the part, not the batch.
Grain cut, strength lost
Bar-stock grain runs one way; your load path may not follow it. Forging follows the part.
THE CONVERSION
Same drawing, new cost structure
| Dimension | Forged blank + CNC (XPF) | CNC from solid |
|---|---|---|
| Blank | Near-net forged blank | Sawn / plate block |
| Machining content | Critical faces & bores only | Whole part |
| Material bought | ≈ finished weight + flash | Finished weight + 50–80% chips |
| Grain flow | Follows part geometry | Straight through, cut at features |
| Unit cost at volume | Falls as die amortises | Flat — always full machining |
Extrusion is another route shops try — see forging vs extrusion vs casting for where each wins.
HONESTY FIRST
When conversion works — and when it doesn’t
- Annual volumeDie cost amortises — the higher the volume, the faster the crossover
- Geometry3-D structural shapes benefit most; flat plates rarely justify tooling
- Strength needsLoad-bearing / fatigue parts gain from grain flow
- Current painHigh buy-to-fly ratio or long spindle hours = biggest savings
- Not a fitR&D prototypes & one-offs — we’ll tell you to keep machining them
PROOF
Case: machined bracket → forged + finished
40% is a reported project outcome, not a standing guarantee — your numbers decide.
HOW IT RUNS
Five steps, one responsible supplier
- Send the drawingSame file your CNC shop gets — STEP / DWG / PDF
- Conversion reviewFeasibility, route, cost range, risks — free, first pass
- Die & samplesIn-house die shop; first articles for your approval
- ProductionForge → trim → CNC finish → anodise, under one roof
- Audit-readyCMM reports, PPAP / FAI documentation on request
FOR CNC SHOPS
Partner route
Run a machining business without a forging line? We supply forged blanks to your drawings — you keep the finishing and the customer.
FAQ
Conversion questions
Will my tolerances survive?
Critical dimensions are machined after forging — you keep CNC-level accuracy where it matters.
What does the die cost?
— itemised in the conversion review; you own the tooling.
How long to first parts?
after die approval — die machining is in-house, so the schedule is ours to control.
Is my annual volume enough?
That’s exactly what the free review answers with numbers, before you commit to anything.
Same drawing. New cost structure.
Free conversion review — feasibility, crossover volume, cost range.