Wheel Care & Protective Coatings

Forging and casting are two very important terms used in the automotive car rims and in the car wheel manufacturing industry. Both forged and cast are the terms used to describe the manufacturing process of wheels. Both cast and forged wheels are made of aluminium but, the method of wheel manufacturing is different! The differentiating factors between the two types is really how the wheels are built. In this article we will be covering the differences between the different types.

Cast wheel vs forge wheel


In the process of casting molten aluminium is poured into a mold by using a vacuum. It is a characteristic of aluminium that if it adopts the shape of the mold in which it has been poured in molten form. In the process of casting, a desired shape of the wheel can be obtained. After pouring the aluminium in the mold it is allowed to cool and after cooling, minor modification can be made in shape if required. Drilling and trimming are common changes that are being made in the final outlook of the wheel. This process of wheel manufacturing is relatively easy and less expensive. The process of solidifying the molten aluminium makes the metal inconsistent due to oxidation, cracking and reduces the integrity of the wheel.


On the other hand, during the forging process solid aluminium (not molten) is used. This solid piece of aluminium is called as billets. Billet pieces are allowed to heat up by putting on heat and an intense hydraulic pressure is applied to form the wheel rims. These wheel rims are then configured into different profiles to make different designs in the final shape of the wheel by using lathes. The raw forging that is formed by the application of heat and pressure is the actual form of aluminium that is used to give any desired shape to the raw forging.

Forged wheels

Although the process of forging is hard and requires great tolerance of the manufacturers, but it is best to obtain the structural integrity of the wheel and to obtain high performance of the wheel. Forging is a costly process of wheel manufacturing, but it gives more benefits to the consumer

The compatibility and structure of the solid aluminium is by all means good as compared to the liquid aluminium that is used in the formation of the cast wheel. The application of pressure during forge wheels manufacturing makes them 3 three superior in performance as compared to the cast wheel.


Forge wheels are 25 to 30% lighter in weight than cast wheels and lighter wheels are highly demanded. The light weight of the forge wheels leads to better fuel efficiency by providing the longer brake system to the car. Forge wheels are durable, consistent and ensures the safe drive. The shape that is acquired after a hard process is fine, durable, less resistant to oxidation and corrosion. The manufacturer has an extensive control over the conditions during the forging process so he can add desired features to the wheel.

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