Optimizing Performance While Maximizing Savings
In today’s highly competitive automotive landscape, every rupee counts. OEMs and Tier suppliers are constantly looking for ways to optimize performance, reduce costs, and maintain quality. One of the most overlooked opportunities lies in switching from machined to forged components — especially when it comes to high-volume fasteners and precision parts.
At Three Sixty Industries (TSI), we’ve helped numerous manufacturers achieve up to 40% cost savings by making this strategic shift. Here’s how.
Understanding the Difference
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Machining involves cutting material away from a solid block (stock) to create the desired shape. While precise, it leads to high material waste, longer cycle times, and higher production costs.
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Cold Forging, on the other hand, involves shaping metal at room temperature using high-pressure dies — delivering near-net shape parts with minimal waste and faster production cycles.
Where the Savings Come From
✅ Reduced Material Waste
Machining can waste up to 60% of the original material. Cold forging uses near 100% of the material, significantly cutting raw material costs.
✅ Lower Cycle Times
Cold forging is ideal for high-speed production — reducing machining time, labor, and energy consumption.
✅ Less Secondary Operations
Forged parts often require less machining or finishing. TSI’s in-house toolroom ensures die design is optimized for accuracy from the start.
✅ Improved Strength = Longer Life
Forged components have superior grain flow and mechanical properties, reducing the likelihood of failure and warranty claims — a hidden cost many OEMs overlook.
Real-World Applications
Many engine, transmission, brake, and structural components that are currently machined can be forged instead — with better cost-performance ratio. At TSI, we’ve helped customers convert items like:
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Mounting brackets
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Bushings & pins
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Engine bolts & studs
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Threaded inserts & weld nuts
Why Partner with TSI?
With 35+ years of forging expertise, a full-fledged in-house toolroom, and process simulation capabilities, TSI is equipped to guide you through the conversion — from design evaluation to full-scale production.
We don’t just manufacture. We engineer cost savings.
Curious if your parts are suitable for forging?
Send us your drawings or specifications — and we’ll help you assess cost, strength, and performance benefits with zero obligation.
Let me know when you’re ready for the third post — or if you want these in a downloadable PDF format for client presentations.
