Casting vs. Forging: Why U.S. Manufacturers Are Converting Castings to Forgings

Why Purchasing Managers Are Choosing Forgings Over Castings and Bringing Manufacturing Back to the U.S.

Across American industry, purchasing managers are taking a hard look at their supplier base, total cost of ownership and risk exposure. In that process, many are discovering that the parts they have always sourced as castings could be better made as forgings, especially when produced in the United States.

What began as an engineering conversation has become a supply chain strategy as more companies work to strengthen domestic production and reduce risk tied to offshore suppliers.

Casting vs. Forging: What’s the Real Difference?

Both processes produce metal components, but the difference in quality and reliability is significant.

• Casting melts metal into a liquid and pours it into a mold to form a shape.

• Forging heats metal until it becomes malleable, then shapes it under pressure to form a denser, stronger structure with refined grain flow.

Because of this process, forgings exhibit superior mechanical integrity and consistent performance, particularly in mission-critical applications.

Why More Buyers Are Moving Away From Castings

For decades, castings were favored for complex shapes and lower up-front tooling costs. But many purchasing teams are finding that the “savings” on paper do not hold up over the product lifecycle.

Common issues with castings include:

• Porosity and inclusions that cause hidden failures or rework

• Inconsistent mechanical properties that complicate qualification or testing

• Higher scrap rates and repair costs that eat into profit margins

• Long overseas lead times that blow up production schedules

Forgings solve these problems before they start. Because the forging process compresses and aligns grain flow, it virtually eliminates porosity and internal defects. The result is stronger, more predictable parts and fewer supply chain surprises.

Near-Net-Shape Forging Opens New Possibilities

Historically, some parts were too complex to forge. That has changed.

What used to require casting can now be forged with modern near-net-shape techniques. Parts can be made more efficiently, using less material and reducing overall cost.

Advances in simulation and process control also help reduce material waste, improve turnaround and provide better cost visibility throughout production.

Forgings Strengthen Domestic Supply Chains

Domestic supply chain resilience has become a top priority for procurement teams across industries. By converting critical parts from castings to forgings and sourcing them domestically, purchasing managers can:

• Reduce supply chain risk from geopolitical and logistical disruptions

• Shorten lead times and improve on-time delivery

• Eliminate dependency on overseas vendors

• Support U.S. manufacturing and workforce stability

• Increase traceability and accountability throughout the supply chain

These are not just patriotic benefits. They are practical procurement wins that protect budgets, schedules and reputations.

Questions Every Purchasing Manager Should Ask

If you are evaluating whether a casting could be converted to a forging, start with a few key questions:

• Are you experiencing high scrap or repair rates?

• Do inconsistent properties create performance or warranty risks?

• Is the component mission-critical or safety-critical?

• Could local sourcing reduce lead times or quality issues?

• Do you have design authority or flexibility to adjust geometry?

A qualified metal forming partner can help assess feasibility, provide comparative cost models and estimate potential lifecycle savings.

The Bottom Line: Forgings Deliver Long-Term Value

While the piece price of a forging may appear higher than a casting, the total cost of ownership tells a different story.

Fewer failures. Less scrap. Shorter lead times. Stronger supply chain control.

That is why purchasing managers across defense, energy, mining and industrial sectors are moving key components to U.S.-made forgings and not looking back.

At Scot Forge, our employee-owners partner with customers to review parts for casting-to-forging conversion, reduce total cost and strengthen domestic supply chains. With in-house metallurgists, forge engineers and testing capabilities, we are equipped to make your sourcing decisions more confident than ever.

Contact us today to evaluate your component and see if a forging is the right fit.