| Item | Description |
|---|
| Product Name | Custom-shaped forgings, non-standard forgings, complex shape forgings, tailor-made forgings to drawings |
| Overview | Custom-shaped forgings refer to non-standard geometry parts (not simple cylinders, rings or blocks) developed entirely according to customer drawings or samples. With 20 years of forging experience, CAE simulation and flexible die design capabilities, we forge complex shapes in one operation – minimizing subsequent machining and saving material & labor costs. Whether symmetrical or asymmetrical, small trial batches or mass production, we provide fast-response custom solutions. |
| Customization Scope | 1. Shapes: steps, recesses, bosses, lugs, forks, curved axes, variable cross-sections, holes, edges, etc.2. Materials: carbon steel, alloy steel, stainless steel (austenitic, martensitic, ferritic), tool steel, duplex stainless steel3. Weight per piece: 0.1 kg – 200 kg4. Annual demand: as low as 50 pieces to start (sample development available) |
| Key Customization Capabilities | - Drawing conversion: Accepts CAD, PDF, 3D models (STEP/IGS) or physical sample scanning- Process design: CAE forging simulation to optimize preform shape and die design, reducing trial runs- Die manufacturing: Fast die design and machining – economical temporary dies (low volume) or production dies available- Flexible production: Combines open-die forging, closed-die forging, ring rolling to suit complexity and volume- Custom heat treatment: Normalizing, Q&T, carburizing, nitriding, induction hardening based on service conditions- Supporting inspections: First-article full dimensional report, material analysis, mechanical testing, NDT |
| Typical Custom-Shaped Examples | - Fork connectors (construction machinery link ends)- Lugs / bracket arms (automotive suspension control arm blanks)- Curved connecting rods (engine connecting rods)- Multi-step shaft with integral flange (gear shaft with disc)- Asymmetric counterweights (crankshaft counterweights)- Grooved or raised valve bodies (ball valve bodies, gate valves)- Irregular agricultural tool holders- Marine special lifting lugs |
| Minimum Order Quantity (Custom) | Sample stage: 1 – 10 pieces (design validation)Small batch: 50 – 500 pieces (simple/low-cost dies)Large batch: 500+ pieces (production dies, best unit price) |
| Sample Lead Time | Simple custom shapes: 15 – 20 working daysComplex custom shapes: 25 – 35 working days (including die design & manufacturing) |
| Mass Production Lead Time | After die validation, regular orders 15 – 30 days (depending on quantity and complexity) |
| Quality Control | 1. First-article full dimensional inspection with report2. In-process inspection and final inspection (dimensions, hardness, NDT)3. 3D scanning comparison service for complex surfaces4. Customer or third-party inspection acceptable |
| Key Advantages (Custom Focus) | 1. Drawings to parts – No standard product catalog needed; we evaluate any drawing or sample2. Fast prototyping – Dedicated project engineer, first sample in as fast as 20 days3. Flexible tooling – Option of low-cost prototype dies (reduced upfront investment) vs. production dies4. No shape constraints – Asymmetric, lugged, variable cross-section, cored, etc.5. Material savings – Near-net shape reduces machining, complex features forged directly6. Batch flexibility – From dozens to tens of thousands, with tiered pricing7. Full transparency – Die drawings, simulation reports, sample inspection reports, production schedule available |
