ForceBeyond provides world-class open die forging (also known as free forging or smith forging) for massive, high-stress industrial applications. By shaping heated metal between multiple flat dies that do not completely enclose the material, we can forge incredibly large and heavy components with unparalleled structural integrity.
Because open die forging does not require the creation of custom, part-specific molds, it is the most cost-effective forging method for low-volume production, rapid prototyping, and parts that are simply too large for closed die presses. We supply heavy-duty forged blocks, cylinders, step shafts, and hubs in a wide range of ferrous and non-ferrous alloys.
Open die forging relies on the skill of the operator and the power of the press to hammer or press the metal into a rough shape, which is then fully machined to print. ForceBeyond handles massive weight capacities and can forge a variety of geometries.
| Forged Geometry | Typical Applications |
|---|---|
| Step Shafts & Spindles | Power generation rotors, marine propeller shafts, and heavy industrial drive shafts. |
| Discs & Hubs | Gear blanks, heavy-duty machinery hubs, and high-pressure pipe flanges. |
| Blocks & Rectangles | Tool steel blanks, massive structural supports, and heavy equipment bases. |
| Cylinders & Sleeves | High-pressure containment vessels, hydraulic cylinders, and extrusion press components. |
| Rings (Mandrel Forged) | Pressure vessel connections and heavy industrial bearing races (for seamless options, see our Rolled Ring Forging capabilities). |
When components are subjected to extreme industrial environments, internal structural flaws can lead to catastrophic failure. Open die forging provides the ultimate metallurgical safeguard.
Open die forging produces a rough shape with extra material allowance. ForceBeyond seamlessly transitions your massive forgings from the press to our heavy-duty CNC machining centers to achieve precise final dimensions.
ForceBeyond provides massive, high-integrity open die forgings to the world’s heaviest industries:
No. Open die forging produces a rough, oversized shape. Because the metal is not constrained by a custom mold, there is a material allowance left on the surface. The forging must undergo heavy CNC machining to reach its final print dimensions.
Almost any forgeable metal can be open die forged, including carbon steel, alloy steel, stainless steel, titanium, and nickel-based superalloys (like Inconel).
While sand casting can produce large parts closer to net shape, castings inherently carry a risk of internal porosity, shrinkage, and a brittle grain structure. Open die forging mechanically works the metal to guarantee a dense, highly refined, defect-free internal structure, which is mandatory for parts subjected to high stress, heavy loads, or extreme pressures.
