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Forging vs Extrusion – What’s the Difference

Forging vs Extrusion

When manufacturing and engineering, there are a variety of processes used to shape different materials. One of the most common types of metal shaping is forging and extrusion. Both methods create durable products, but the process for each differs. Let’s explore how these two approaches differ and how each should be used in various situations.

Forging Explained

Forging is a process by which metal is heated until it becomes malleable and then pounded or pressed into a desired shape. This process dates back centuries, as it was first used in ancient times to make weapons. The biggest advantage of forging is that it creates a stronger product than other methods, such as casting or welding. In addition, forged parts have greater fatigue strength, meaning they can withstand more wear and tear over time without breaking down. As such, this method is often used when creating parts that will be put through intense strain or stress, like car engines, axles, and crankshafts.

Extrusion Explained

Extrusion is another common metal shaping technique where heated material (usually aluminium or steel) is forced through a die with an opening that matches the desired shape of the finished product. The material then cools down to its solid form once it has been pushed through the die opening. This method can produce complex shapes quickly and efficiently since no additional cutting or machining is required afterwards. It also produces parts with consistent dimensions from start to finish since all pieces are produced from the same die opening—something that cannot be achieved with casting or welding processes. However, extruded pieces tend to be weaker than those created using forging due to their lack of uniform grain structure along the length of the part.

Difference Between Forging and Extrusion

  • Forging is a manufacturing process in which metal is heated and then shaped using hammers or presses.
  • Extrusion is a manufacturing process in which metal is forced through a die to create a desired shape.
  • Forging is typically used for larger, more complex parts, while extrusion is typically used for smaller, simpler parts.
  • Forging can result in stronger, more durable parts, while extrusion can result in parts with a more consistent cross-section.
  • Forging typically requires more energy and time than extrusion, but the end result is often worth the investment.


Both forging and extrusion provide advantages depending on what type of product you’re trying to create—from small components like bolts and screws to large machines like bulldozers and cranes. Forging creates stronger parts, while extrusion provides faster production times with consistent results every time. Ultimately, understanding the strengths and weaknesses of both processes will allow you to choose which one will work best for your particular application so you can get your job done right the first time!

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