Forged wheels are manufactured through a controlled, high-pressure forming process that prioritizes material density, structural integrity, and precise engineering tolerances. At RRT Forged, the process is designed to deliver wheels that are lighter, stronger, and more consistent than cast alternatives.
Here is how the process works, step by step.
The process begins with a solid billet of high-quality aluminum alloy, typically 6061-T6. This alloy is chosen for its balance of strength, fatigue resistance, and machinability. Unlike cast wheels, no molten metal is poured into a mold. The aluminum starts as a dense, uniform block with no inherent porosity.
What this means in practice is a stronger base material before any shaping begins.
The aluminum billet is heated to a controlled temperature and then placed into a forging press. Extreme pressure, often several thousand tons, is applied to compress and shape the metal.
This pressure forces the aluminum’s grain structure to flow in the direction of the wheel’s design. The result is a much tighter grain alignment compared to casting.
What this really means is higher strength with less material.
Rather than forging the final wheel shape in one step, the billet is typically forged into a near-net preform. This preform already resembles a wheel blank, with the basic barrel and center structure established.
This step ensures:
Once forged, the wheel blank is CNC-machined to exact specifications. This is where the final design takes shape, including:
Because the forged blank is already strong, engineers can remove excess material without compromising structural integrity.
This is where forged wheels gain their reputation for being both light and durable.
After machining, the wheel undergoes heat treatment to restore and stabilize the aluminum’s mechanical properties. This step improves:
Heat treatment ensures long-term performance under real-world loads, including high-speed driving and aggressive cornering.
The final stage is surface finishing. Depending on the specification, this may include:
Each finish is applied with durability and consistency in mind, not just appearance.
Compared to cast wheels, forged wheels offer:
For performance vehicles and high-load applications, forging is not a cosmetic upgrade. It is a structural one.
Forged wheels are made from a solid aluminum billet that is shaped under extreme pressure. This process compresses the metal’s grain structure, creating a wheel that is stronger, lighter, and more durable than traditional cast wheels.
Cast wheels are made by pouring molten aluminum into a mold. This can introduce air pockets and inconsistencies in the metal. Forged wheels, by contrast, start as a solid billet and are compressed under high pressure, resulting in superior strength and a lower weight.
Yes. While they are more expensive than cast wheels, the benefits include:
Absolutely. The high strength-to-weight ratio of forged wheels makes them ideal for high-performance applications, track use, and vehicles that experience heavy loads or high cornering forces.
Forged wheels can be 15–25% lighter than cast wheels of the same size. This reduction in unsprung mass improves acceleration, braking, and cornering performance.
Yes. RRT Forged wheels can be CNC-machined to exact specifications, allowing custom spoke designs, offsets, finishes, and paint options. Each wheel is engineered to maintain strength while achieving the desired aesthetics.
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