Differences Between Forging and Casting

What is forging? Forging is a process that changes solid metal by applying force. In contrast, casting shapes metal by pouring it into molds. Choosing one method over the other affects how strong and reliable the parts will be. Studies show that casting can produce strong metal if the cooling process is carefully controlled, but casting may result in metal that is less tough. Forging improves the grain structure and reduces defects, making metal parts more reliable.
The worldwide casting and forging market may reach $245 billion by 2032, driven by demand from car and airplane manufacturers for strong, lightweight metal. When deciding between these methods, factors like grain structure, defect rates, and the intended use of the part are important. Understanding what is forging and how it compares to casting helps manufacturers choose the best process for their needs.

Key Takeaways

• Forging uses force to shape solid metal. This makes parts strong and dependable.
• Casting melts metal and pours it into molds. This helps make big or tricky shapes.
• Forged parts have grains that line up. They have fewer problems and are stronger than cast parts.
• Casting works well for detailed, hollow, or big parts. But it can have more problems.
• Forging costs more at first. But it saves money later because custom metal parts last longer and stay strong.
• Casting costs less at the start. It is good for making many custom metal parts or shapes that are hard to make.
• Use forging when you need parts that are very strong, tough, and safe.
• Use casting when you need parts with tricky shapes, big size, or lower cost.

What is Forging

Forging is a way to shape metal using force. It does not melt the metal. The metal stays solid while its shape changes. This method makes the inside grain structure better. That means the metal gets stronger and works well in tough jobs.

Forging Processes

Pressing and Hammering

Forging starts with pressing or hammering metal. Big machines push or hit the metal hard. This force changes the shape but does not melt it. Here are the main steps in forging:

1. Open Die Forging (Initial Rough Shaping): Workers use tools to move the metal. They upset, fuller, edge, or cog it. This step sets up the grain structure for more strength.
2. Impression Die Forging (Detailed Geometric Forming): The metal goes into dies with special shapes. This step gives the part its final shape and makes sure it fits the design.
3. Finishing Operations (Final Sizing and Accuracy): Workers trim and size the part. This makes sure it is the right size and smooth.
4. Temperature and Friction Control: Hot forging makes the metal easier to shape. Lubrication and heat control stop defects and help the metal flow.
5. Grain Structure Control: Each step helps make a strong grain structure inside. This makes the metal tough and strong.
6. Integration with Other Manufacturing: Sometimes, forging mixes with machining. This gives high accuracy and great mechanical properties.

Grain Flow

Forging lines up the grain flow with the part’s shape. This makes the metal stronger against pushing and cutting forces. The process breaks up crystals and closes pores inside. It also spreads alloy elements evenly. These changes make the metal tough and less likely to break.

Forging Properties

Strength

Forged parts are stronger than cast or machined ones. Forging makes the grains smaller and spreads alloys evenly. This helps the metal resist cracks and bending. Hot forging changes the inside structure. It boosts strength, toughness, and heat resistance.

Durability

Forging makes metal last longer by removing defects. It crushes empty spaces and gets rid of porosity. It also stops segregation that happens in casting. Good control of heat and shaping makes the grain structure even. This gives the metal better toughness and longer life. Alloys forged with care bend more and resist breaking. They work well in important jobs.

Note: Forging cuts down on defects like unfilled spots, cold shuts, scale pits, die shift, flakes, and surface cracks. Good die design and heat control help stop these problems. This makes metal parts more reliable.

Casting

Casting is a basic way to make metal parts. Engineers use it to create shapes that are hard to make by other methods. The metal forming process melts metal and pours it into a mold. The metal cools down and becomes solid in the mold’s shape. It lets people make big or detailed metal casting parts. This is why it is often chosen for special designs.

Casting Process

Melting and Pouring

First, workers melt the metal or alloy. They heat it until it turns into a liquid. Next, they pour the hot metal into a mold. They must watch the temperature and how fast they pour. This helps stop problems like holes or missing spots. How fast the metal cools changes the internal grain structure and relative strength.

Mold Formation

Making the mold is very important in casting. Workers start with a pattern that shapes the mold. They think about how the metal will shrink and where the mold will open. Next, they make cores for hollow spaces inside the metal casting part. They pack sand or other stuff around the pattern to form the mold. The mold must not break from the hot metal and must keep its shape.

Note: A good mold gives a smooth surface and the right size. If the mold is made well, there are fewer mistakes and better results.

The steps in casting are:

1. Patternmaking: Makes the template for the mold and plans for shrinking.
2. Coremaking: Builds hollow or tricky shapes inside the part.
3. Molding: Forms the space for the metal using sand or other things.
4. Melting and Pouring: Heats the metal and pours it into the mold.
5. Cooling and Solidification: Controls how the grains form and how strong the part is.
6. Ejection, Cleaning, and Finishing: Takes the part out and makes it smooth.

Casting Properties

Internal Grain Structure

Casting changes the way grains form inside the metal. The grains grow in random ways as the metal cools. This makes the inside less even than forged metal. How fast the metal cools, what is in the alloy, and any dirt in the mix all change the grain size. If the metal cools quickly, grains are smaller but there may be more holes. Cast metal is usually not as strong as forged metal because of this.

Defects

Casting can cause many kinds of problems in the metal. These problems can make the part weaker or less safe. Some common problems are:

• Gas porosity: Air bubbles get trapped and make tiny holes.
• Shrinkage: The metal gets smaller as it cools and can crack.
• Metallurgical defects: Bad cooling or wrong mix makes weak spots.
• Pouring defects: Not enough metal fills the mold or cold lines form.
• Mold material defects: The mold breaks or leaks, making rough spots.

These problems happen when air gets trapped, the metal does not flow well, or the temperature changes too much. Even with these issues, casting is still needed to make big or tricky parts that forging cannot do easily.

Process Comparison

Step-by-Step

It is important to compare forging and casting. This helps manufacturers pick the best way to make metal parts. Both methods shape metal, but they use different tools and steps. The table below shows how each process works from beginning to end:

Aspect	Casting Process	Forging Process
Equipment	Molds or dies to contain molten metal	Dies and hammers or presses to shape solid metal
Temperature	Metal heated until molten (liquid state)	Hot forging: metal heated below melting point; cold forging: room temperature
Time	Depends on cooling and solidification of molten metal	Hot forging may require reheating if metal cools too much; cold forging is faster but limited in complexity

Casting starts by heating metal until it is liquid. Workers pour the liquid metal into a mold. The mold gives the part its shape. How fast the metal cools and hardens is important. Cooling time changes the grain structure and strength of the part.

Forging uses solid metal from the start. Workers use hammers or presses to shape the metal. Hot forging heats the metal but does not melt it. This makes the metal easier to form. Cold forging shapes the metal at room temperature. Sometimes, hot forging needs more heat if the metal cools down. Cold forging is faster but cannot make very complex shapes.

Differences

Forging and casting make parts with different features. The biggest differences are in grain structure, strength, and how many defects can happen.

• Grain Structure:
  Forging lines up the grain flow with the part’s shape. This makes the part stronger and tougher. The process crushes empty spaces and spreads alloy elements evenly. Casting lets grains grow in random ways as the metal cools. This can make cast parts weaker and easier to break.
• Strength:
  Forged parts are stronger than cast parts. Forging makes the grain structure better and removes defects. Cast parts can be weaker because of trapped air, shrinking, or uneven cooling.
• Defect Rates:
  Forging lowers the chance of defects. It closes pores and gets rid of most inside flaws. Casting can cause problems like gas bubbles, shrinking, and cracks. These problems can make the part weaker or break in tough jobs.

Tip: Forging is best for parts that need to be strong and reliable. Casting is good for parts with tricky shapes or big sizes when strength is not as important.

Both forging and casting are important in making things. The choice depends on what properties are needed, how complex the part is, and how many parts are made.

Material Properties

Strength

Forging makes parts stronger than casting. It shapes metal while it stays solid. This helps the grains inside line up with the part’s shape. Lined-up grains make the part tough and hard to break. Casting pours metal into a mold. This causes grains to form in random ways. Random grains can lead to more defects. These things change how strong each method is.

The table below shows how strong forged and cast metals are:

Material & Condition	Typical Ultimate Tensile Strength (Su) MPa
Forged Aluminum 6061-T6	340 – 389
Cast Aluminum A356-T6	252 – 283
Forged Aluminum 7075-T6	314 – 580
Cast Aluminum A356-T6 (varied)	252 – 283
Forged Steel 4340	Up to 1172
Cast Steel 8630	BHN ~254 (lower strength)
Steel A36 (forged/wrought)	Su ~540
Ultra-high strength steels (forged)	Up to 1600+

Forged metals are usually stronger than cast metals. Some forged steels’ compressive strength can be stronger than 1500 MPa. Forging also helps parts last longer when used over and over. Fatigue strength is better with forging, but testing can be tricky. Still, forged parts often work better for a long time.

Durability

Forging makes parts last longer by fixing defects. It crushes empty spaces and closes holes inside. This makes the part stronger and less likely to crack or bend. Cast parts have more holes and shrinking, which makes them weaker. Forged parts keep their shape and strength after many uses. This is good for jobs where safety matters.

Note: Forged parts work better in tough places like cars and planes.

Grain Structure

Forging improves the grain structure of metal. The grains line up with the force used. This makes the part stronger and tougher. It also helps the part bend without breaking. Casting makes grains form in random ways. This can cause more holes and shrinking. These problems make the part weaker and easier to break.

• Forging lines up grains for more strength.
• Casting makes random grains, which can cause defects.
• Forging gets rid of gas pockets and holes.
• Casting leaves more defects that can weaken the part.

Forged parts are stronger, last longer, and work better because their grains are lined up and they have fewer defects.

Design Flexibility

Complexity

Casting is the best way to make very complex shapes. Engineers can design parts with tiny details and hollow spaces. Forging cannot make these shapes easily or cheaply. Molten metal fills every part of the mold. This lets casting capture small textures and tricky shapes. Casting is great for industries that need special metal parts.

Forging shapes metal by pressing it hard. It does not melt the metal. This makes the grains line up and the part stronger. But forging cannot make very detailed shapes. It works best for simple parts. Closed-die forging can make some shapes, but not as many as casting. Forging cannot make sharp corners, thin walls, or hollow spots well. To get the right size or smooth surface, workers may need to machine the part more. This adds cost and takes more time.

Note: Forging costs more to set up for complex shapes. It is not a good choice for small batches or when designs change often.

Here is a quick comparison:

• Casting makes detailed shapes, hollow spaces, and fine textures in one step.
• Forging can only make simple shapes and needs extra work for details.
• Casting saves money for tricky custom parts, especially if you need only a few.

Size

The size of the part helps decide between forging and casting. Forging has limits because it uses force on solid metal. Most forging machines can only make parts up to 18 inches long and 100 pounds heavy. Bigger parts need stronger machines and special tools. These are not always easy to get or cheap.

Casting does not have these limits. Molten metal can fill molds of almost any size. This means casting can make very big parts. Some castings weigh thousands of pounds and have shapes forging cannot do. Casting is best for huge custom parts used in energy, mining, and big machines.

Process	Maximum Part Size	Maximum Weight	Typical Application
Forging	Up to 18 inches in length	Up to 100 pounds	Small, strong parts for important jobs
Casting	Thousands of pounds	Thousands of pounds	Big, complex, or custom parts with lots of detail

Tip: If you need big or very detailed parts, casting gives you the most freedom and works best.

Cost and Production

Cost Factors

Cost is very important when picking forging or casting. Forging needs more money at the start. You must buy dies, presses, and pay skilled workers. Using strong alloys like 7075 aluminum costs more. Metal prices can change and affect forging costs. Forging uses a lot of energy to heat metal. Skilled workers and toolmakers get paid more now. These things make forging expensive at first. But making more parts can lower the cost over time.

Casting usually costs less to begin with. Standard molds are cheaper to make. Special or tricky molds can cost more. Casting may waste more metal because of mistakes or extra metal. Both forging and casting might need extra work like polishing or machining. This helps the part look good and fit right. The table below shows the main cost differences:

Cost Factor	Forging Characteristics	Casting Characteristics
Initial Setup and Tooling	High initial costs due to expensive dies and equipment; costs increase with customization	Lower initial tooling costs for standard molds; complex/custom molds increase expenses
Manufacturing Cost Per Piece	Generally higher per piece but decreases with volume	More affordable at high production volumes
Investment Cost	Requires large capital expenditure for dies and equipment	Lower investment needed for mold creation and setup
Material Costs	Reduced material waste due to compression and efficient use	Potential for increased waste from defects and excess metal in molds
Post-Processing Costs	Often requires extensive machining and polishing for surface finish	May also require polishing or machining to meet tolerances and surface quality
Production Scale Suitability	More suited for medium to low production volumes due to tooling costs	Ideal for high-volume production due to scalability and lower per-piece cost at scale

Tip: Companies should think about both starting and long-term costs before choosing how to make parts.

Production Volume

How many parts you make changes which process is best. Forging works well for making lots of parts. The cost for dies and machines spreads out over many pieces. This makes each part cheaper when you make more. Using machines and faster work helps save money in big factories. Forging uses less energy for each part when making many at once. It only heats metal until it is soft, not liquid.

Casting is good for making a few or many parts. Lower mold costs help with small batches or custom shapes. Casting can make many parts at the same time. This helps finish jobs faster for some designs. Casting uses more energy for big or thick parts. New casting methods save energy, but mistakes and mold damage can still cost more later.

Here is a quick look at making lots of parts and saving money:

• Die forging gets cheaper when you make more parts.
• Casting is good for small batches and tricky shapes.
• Forging makes strong parts and wastes less metal.
• Casting needs more fixing and cleaning, especially for exact jobs.

Aspect	Forging	Casting
Initial Tooling Cost	Higher tooling and equipment costs	Lower upfront tooling costs
Production Volume	More cost-effective at high volumes due to spreading tooling costs	More cost-effective for small production runs
Material Waste & Durability	Lower material waste, longer tool life, produces stronger, more durable parts	Higher material waste, molds wear out faster, parts prone to defects
Post-Processing & Maintenance	Minimal post-processing, lower maintenance costs	Higher maintenance, machining, and defect-related costs
Production Speed	Faster for high-strength parts in large quantities	Faster production times for complex parts, especially in small to medium volumes
Industry Applications	Automotive, aerospace, oil & gas (high-strength, durable parts)	Construction, medical (complex shapes, intricate designs, small batches)
Lifecycle Cost Consideration	Higher upfront cost offset by long-term savings and durability	Lower initial cost but potentially higher total cost due to defects and maintenance

Note: The best choice depends on the part’s size, shape, strength, and how many you need.

Surface Finish and Tolerances

Finish Quality

Surface finish means how smooth or rough a metal part feels. Forging usually makes smoother parts than casting. The forging process presses metal hard against the die. This pressing action smooths the surface and shapes it well. Forged parts often need less extra work to look nice.

Casting often leaves a rougher surface on the part. Molten metal fills the mold, but it can pick up tiny flaws. These flaws come from the mold or trapped air. Cast parts usually need more polishing or machining to get smooth.

Here are some main differences in surface finish:

• Forged parts come out of the die with a finer surface.
• Forging presses out flaws and makes the part look even.
• Cast parts often have rough spots or small holes from cooling.
• Forged aluminum parts resist fatigue and impacts better, which helps the surface stay strong.

Tip: Forging can save time and money on finishing steps. This is helpful for parts that must be very smooth.

Tolerance Levels

Tolerance means how close a part is to its planned size and shape. Tighter tolerances help parts fit together better and work well. Forging usually gives tighter tolerances than casting. The controlled force in forging shapes metal with high accuracy. This means forged parts are closer to the right size.

Casting tolerances change based on the method used. Some casting, like die casting, can be very accurate. But most cast parts still need extra machining to meet strict rules. The table below shows typical tolerances for each process:

Process	Typical Tolerance (per linear inch)	Impact on Product Quality
Forging	±0.1 mm to ±0.5 mm	High dimensional accuracy; less need for extra machining
Sand Casting	±0.3 mm to ±3 mm	Good for large parts; moderate precision
Investment Casting	±0.1 mm to ±0.3 mm	High accuracy for small, detailed parts
Die Casting	±0.02 mm to ±0.1 mm	Excellent for high-volume, tight-tolerance parts
Gravity Casting	±0.1 mm to ±0.5 mm	Moderate precision; cost-effective for medium parts

Forged parts often meet tight tolerances right away. This means less extra work is needed to make them fit. Cast parts, especially sand or gravity castings, may need more work to be precise.

Note: Tighter tolerances make products better but can cost more. CNC machining after forging or casting can help reach the strictest tolerances if needed.

Advantages of Forging

Strength Benefits

Forging makes metal parts much stronger than casting. Engineers pick forging when parts need to hold heavy weight or face lots of use. The process lines up the grains inside the metal. Lined-up grains make the part tougher and help it last longer. When metal is forged, it also gets harder and more durable. Forged parts can handle more pulling and bending than cast parts.

Tests show these differences clearly. Forged steel is strongest along the grain flow. Cast steel has grains in random directions, so it is weaker. Forged steel lasts longer in tough jobs, especially where there is a lot of stress. The table below shows how forged and cast steel compare:

Property	Forged Steel	Cast Steel
Grain Structure	Aligned, continuous	Random, possible voids
Tensile Strength	Higher	Lower
Fatigue Resistance	Superior	Lower
Defect Rate	Reduced likelihood of defects	More common defects

Forging helps get rid of holes and trapped stuff inside the metal. This makes the part stronger and helps it last longer. Many industries use forging for parts like crankshafts and connecting rods. These parts must be strong and not break easily.

Tip: Forging is best for car and airplane parts that must work in hard conditions.

Reliability

Forging makes parts that are very reliable. The process gives the metal a better grain structure and fewer flaws inside. This means the part is strong and works well every time. Forged parts can handle shaking, heat, and stress without breaking.

Car and airplane makers use forging for important parts like landing gear and engine blades. These parts cannot fail when in use. Forged stainless steel is pressed so the grains line up and defects go away. This makes the metal tough and safe.

The table below shows how forged and cast parts compare in reliability:

Feature	Forged Components	Cast Components
Grain Structure	Refined, aligned	Random, possible voids
Strength	Higher	Lower
Ductility	Better deformation capacity	More brittle
Fatigue Resistance	Superior	Lower
Typical Applications	Critical aerospace, automotive	Decorative, non-structural
Cost	Higher initial, better long-term	Lower initial, higher risk

Forging keeps the metal strong and safe, so it is great for parts that must not fail. Fewer defects mean less fixing and fewer problems later. Companies use forging for parts that need to last and keep people safe.

Note: Forging is the most reliable choice for parts that must not break.

Advantages of Casting

Design Benefits

Casting lets manufacturers make parts with many shapes. They can create thin walls and hollow spaces inside parts. Other methods cannot do this as easily. Some casting, like investment casting and die casting, makes very detailed parts. These parts often need little extra work after. Casting works with many metal alloys, like superalloys and aluminum alloys. This helps engineers make products that are strong, last long, and weigh less.

Manufacturers use machines and special software to control casting. These tools help stop mistakes and make work faster. Quality checks, like 3D scanning and watching in real time, make sure each part is made right. Casting can make parts almost the same shape as needed. This means less wasted metal and less extra work.

Some main design benefits of casting are: making tricky shapes and hollow spots, using many types of metals, getting good detail with little finishing, making big or detailed parts quickly, and keeping quality high with new tools.

Casting can also make very big parts. Factories can make more parts without losing detail or quality. This is why casting is used in cars, planes, and energy jobs where size and shape are important.

Note: Casting is best for parts with tricky shapes, hollow spaces, or when engineers want to join many pieces into one.

Cost Efficiency

Casting saves money, especially when making lots of parts. It is good for fast work and tricky shapes, so it costs less for many jobs. Forging costs more at the start and takes longer, especially for big or hard shapes. Casting can do these jobs for less money.

Factories often change many small parts into one big casting. This saves work, cutting, and putting parts together. Sometimes, switching to casting saves more than 15% of the cost. For example, a heavy stainless steel part got cheaper and better when made by casting instead of building it from pieces.

Centrifugal castings are used instead of forgings for tough jobs. They do not crack as easily and last longer. This means less money spent on fixing or replacing parts. Casting tools for airplane parts can last much longer than tools for built parts. This means less money spent on new tools.

Some key points about saving money with casting are: making big or tricky parts as one piece, needing less work and fewer workers, wasting less metal, making parts faster for big orders, and using tools that last longer.

Tip: Companies that want to save money and make tricky or many parts often pick casting because it is fast and flexible.

Casting is the best way to make big, tricky, or many parts for less money. Car, building, and energy companies use casting for these reasons.

Applications

Forging Uses

Forging is used when parts must be strong and last long. Companies pick forging for products that face heavy loads or tough places. The forging process changes the grain inside the metal. This makes the part stronger against hits and cuts. Forged parts are about 26% stronger than cast ones. They also last longer and do not break as easily.

Many industries use forging for important jobs:

• Car and truck makers use forging for wheel spindles and axles. These parts move a lot and take heavy stress.
• Airplane companies pick forging for wing roots and landing gear. These parts must be strong but not too heavy.
• Oil and gas workers need forged valve bodies and flanges. These parts face high pressure and harsh chemicals.
• Mining uses forged gears and rock tools. Forged parts help machines work longer with less stopping.
• Power plants use forged turbine parts and couplings. These must be tough and work well for a long time.
• Ships and trains use forging for big parts that face pulling and rough use.
• Hand tools like hammers and wrenches are forged for extra strength.
• Big machines and building equipment use forged rods and discs for safety and long life.

Forging stops problems like holes and shrinking. This is why it is picked for parts that cannot fail. Many products need forging to stay safe and work well.

Casting Uses

Casting is best for making tricky shapes and big parts. Companies use casting when they need detailed designs or want to save money. Casting can make thin walls and hollow spots that forging cannot do.

Casting is used for many commercial applications:

• Car engines use casting for cylinder heads and blocks. Casting makes it easy to form inside paths.
• Airplane makers use casting for turbine blades and covers. These need to be exact and made from special metals.
• Medical companies use casting for implants and tools. These parts need smooth surfaces and special shapes.
• Big machines use cast housings and pump bodies. Casting is good for large, strong parts.
• Building and energy jobs use casting for valves and pipe fittings.

Different casting methods fit different needs. Die casting makes exact car and airplane parts. Investment casting is used for tricky shapes in medicine and planes. Sand casting is good for big machine parts. Gravity casting works for simple things like car wheels.

Design and cost matter when picking casting. The metal, weight, and shape change the price and how easy it is to make. Companies use casting for parts that need little extra work and can be made in large numbers. Tests and checks make sure cast parts are safe, especially for important jobs.

Casting is needed for parts with hard shapes, big size, or when making many at once for less money.

Choosing Forging or Casting

Picking the right way to make metal parts takes careful thought. Each method has its own good and bad points. Makers must look at these to be sure the part will be strong, not cost too much, and fit the design. They also need to think about how many parts they will make. Here is a checklist to help decide:

• Check how big and heavy the part is.
• Look at how tricky the shape is.
• Think about what strength and toughness the part needs.
• Guess how many parts you will make.
• Figure out how much tools and machines will cost at first.
• Think about how much metal will be wasted.
• See how much work and power are needed.
• Check if the part needs extra work after making it.

Decision Factors

Performance

How well the part works is very important. Forging makes the grains inside the metal line up. This makes the part stronger and tougher. Forged parts do better in hard jobs, like in cars or planes. They also have fewer hidden problems inside. This means they are safer and last longer.

Casting makes the metal the same in every direction. This is good for parts that do not need to be strong in one way. But casting can get tiny holes inside, which can make the part weaker. Makers pick casting for parts with hard shapes when even strength is enough.

Tip: If a part must be very strong and safe, forging is the best choice.

Cost

How much it costs is a big deal. Forging costs more at the start because special tools and big presses are needed. But forging wastes less metal since the shape is close to the final part. It also needs skilled workers and uses more energy, which adds to the price.

Casting costs less to start, especially for big or tricky parts. Molds are cheaper and can be used again, so it is better for making lots of parts. But casting may need more cutting or polishing, which can make each part cost more.

Factor	Forging	Casting
Performance	Strong, tough, lasts long	Same strength all over, can get holes
Cost	Costs more at first, wastes less metal	Cheaper tools, better for big batches
Design	Simple shapes, not many details	Hard shapes, big parts
Quantity	Good for small or medium batches	Best for making lots of parts

Design

How tricky the part is changes which way is best. Forging is good for simple, strong shapes. It cannot make thin walls or holes inside easily. Sometimes, extra cutting is needed to get the right shape, which takes more time and money.

Casting is great for making parts with lots of details. It can make thin walls, hollow spots, and hard shapes. Makers can join many pieces into one part with casting. This saves time and space. Casting is best for parts that need special shapes or many features together.

Note: If a part has shapes that are too hard to cut or forge, casting is the smart way to go.

Quantity

How many parts you need matters a lot. Forging is better for making a few or a medium number of parts. The high cost for tools and setup is spread over fewer parts. This makes forging not as good for huge batches unless the part must be very strong.

Casting is great for making lots of parts fast. It is cheaper for each part when making big batches. Makers use casting when they need many parts that are all the same and have tricky shapes.

• Forging: Good for small or medium batches when strength is most important.
• Casting: Best for big batches and hard shapes.

Makers should pick the way that fits what the part needs, thinking about strength, price, shape, and how many are needed.

Forging and casting are both good ways to make metal things. Forging makes parts that are very strong and last a long time. Casting is better for making big or tricky shapes. Here is a simple guide:

1. Pick forging if you need strong, exact, and dependable parts.
2. Pick casting if you want detailed shapes, lower price, or bigger size.

Need	Forging	Casting
Strength	Best choice	Good for low stress
Complexity	Limited	Excellent

Choosing the right way helps your parts work well and not cost too much.

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