Custom forgings from India go from a drawing to a first lot through die design, die making, a tryout of sample forgings, inspection, and then production. The die is the long-lead item, so the timeline depends mostly on how fast it can be designed, made and approved.
This article follows that route so you know what to send and what to check.
What do you send to start?
Send a clear drawing with dimensions, tolerances, material grade, heat treatment, hardness range and any test requirements. Include the annual quantity and the first order size, because they decide whether open-die, closed-die or ring rolling is the right process. Open-die versus closed-die forging explains the choice.
The maker will usually add forging allowances and draft angles to turn your finished-part drawing into a forging drawing. Ask to approve that drawing before die making begins.
How does die development work?
For closed-die forging, the maker designs and cuts steel dies that shape the hot metal. Die steel, die life and the number of forging stages affect the quality and cost.
The steps are:
- Forging drawing and die design, which you review and approve.
- Die manufacture, normally by CNC and electrical discharge machining.
- Tryout forgings, which are checked for fill, grain flow and dimensions.
- Adjustments to the die, followed by a second tryout if needed.
What should the first lot be checked for?
Insist on a first-article report before production starts, with dimensions against the drawing, material test certificate, heat-treatment record and hardness results. Steel grades for forgings, heat treatment for forgings and the material test certificate EN 10204 3.1 explain what each document should show.
Ask about surface defects such as laps and cracks, and whether magnetic-particle testing is needed for safety parts.
Dimensional checks should include the points that matter after machining, such as the machining allowance on critical faces and the distortion after heat treatment. A forging that is in tolerance on the drawing but too thin to machine is of no use. Ask for a section cut of one early sample to look at grain flow, if the part is critical.
Who owns the die?
Settle this in writing before you pay for tooling. Your agreement should say that the die belongs to you, stays at the maker, is marked with your name, and cannot be used for others. Also agree on who pays for maintenance or replacement once the die wears out. Tooling cost and ownership covers the usual arrangements. Plan the quantity of your first order against the maker's minimum, which the MOQ for castings and forgings discusses.
Plan the timeline with your own milestones. Die design and approval, die making, tryout, correction, first-article inspection and production each take their own time, and corrections can repeat. Ask the maker to give you a dated schedule, and ask which stages run in parallel, such as material purchase during die making.
Finally, specify packing. Forgings that are machined or finished need protection against rust and knocks during sea freight, and the maker should tell you how they will be oiled, wrapped and crated.
Next step
We find and audit forging plants, check first-article reports and certificates, have lots tested, and supervise loading. To take a forging from drawing to first lot, book a free sourcing review.