Closed Die Forgings
Aluminum bar components forged to near-net shape using closed dies, minimizing raw material waste and machining costs while delivering consistent mechanical properties and dimensional accuracy across production runs.
MTS Forge delivers precision-engineered forged aluminum bars built for demanding applications across aerospace, defense, and power generation. With metallurgical expertise developed over 40 years, our closed-die and custom forging processes produce aluminum bar stock with superior grain structure, tighter tolerances, and better mechanical performance than cast or machined-from-bar alternatives — all made in America.
From closed-die aluminum forgings to custom bar profiles, we deliver precision forged solutions that reduce costs and exceed specification.
Aluminum bar components forged to near-net shape using closed dies, minimizing raw material waste and machining costs while delivering consistent mechanical properties and dimensional accuracy across production runs.
Bespoke forged aluminum bars engineered to your exact dimensional and alloy specifications. From small structural components to large structural profiles, we forge to your blueprint with made-in-America craftsmanship.
Contour forging of aluminum bars into complex shapes and profiles, leveraging our extensive in-house tooling inventory to produce parts efficiently and at competitive cost without unnecessary machining stock.
Production of upset forged aluminum rings, cylinders, and bar-derived components up to 26 inches in diameter and 1,500 lbs per piece, across nearly all commercial aluminum grades.
In-house normalizing and thermal processing of forged aluminum components to relieve internal stresses, refine grain structure, and optimize tensile strength, toughness, and machinability for downstream applications.
Post-forge rough machining brings forged aluminum bars to near-net shape, removing flash and surface irregularities in-house to reduce lead time and eliminate the need for a separate machining vendor.
Forged aluminum bars from MTS Forge offer a measurable advantage over cast or machined-from-bar alternatives — tighter grain flow, higher tensile strength, and better fatigue resistance in every piece. Our large tooling inventory means we forge near-net shapes rather than cutting away expensive billet, delivering significant cost savings per unit. With 40 years of metallurgical expertise and in-house heat treatment and rough machining, we provide a vertically integrated forging solution trusted by aerospace, defense, and power generation manufacturers.
See how MTS Forge has delivered precision forged aluminum bars that meet the strictest aerospace, defense, and nuclear standards.
Four decades of forging excellence, metallurgical know-how, and vertically integrated capabilities set MTS Forge apart.
Founded by metallurgists, our team applies deep material science knowledge to every aluminum forging order.
Our large proprietary tooling inventory lets us forge near-net aluminum shapes, cutting your per-unit material and machining costs.
Mil I 45208, NCA 3800, and Mil Q9858 certifications ensure every forged aluminum bar meets stringent traceability and quality standards.
All forged aluminum bars are manufactured at our Coatesville, PA facility, supporting domestic supply chains for defense and aerospace programs.
Industry veterans with decades of hands-on metallurgical and forging expertise.
Co-Founder
Stephen Carr co-founded Manufacturing & Technical Services, Inc. — MTS Forge — in 1986 alongside Edward Waddell. With a formal metallurgical background, Stephen brought deep scientific understanding of metal grain structure, alloy behavior, and forging mechanics to the company from day one. His expertise in forging practices shaped MTS Forge's commitment to producing components that consistently outperform machined-from-bar or cast alternatives in strength and fatigue resistance. Over four decades, Stephen's leadership has guided the company through significant technological investment, expansion of its forging capabilities, and the establishment of a rigorous quality culture that now underpins MTS Forge's reputation as a trusted supplier to aerospace, defense, commercial nuclear, and power generation industries across the United States.
Co-Founder
Edward Waddell co-founded MTS Forge in 1986, bringing a metallurgical background and extensive hands-on knowledge of forging processes that became the technical foundation of the company. Edward's understanding of material science — from aluminum and alloy steel behavior under compressive force to post-forge heat treatment requirements — informed MTS Forge's early investment in in-house capabilities including tooling design, normalizing heat treatment, and rough machining. Together with Stephen Carr, Edward built MTS Forge on twin pillars of quality and service, principles that continue to define the company's approach to every forged aluminum bar, closed die component, and custom forging it produces for customers in aerospace, defense, power generation, and beyond.
Yes, 6061-T6 aluminum is one of the most commonly forged aluminum alloys. The T6 designation refers to the solution heat-treated and artificially aged temper applied after forging, which maximizes yield strength and hardness. Forging 6061 aluminum refines its grain structure along the part's contour, resulting in significantly better fatigue resistance and tensile strength compared to 6061-T6 bar stock that is simply machined from extruded material.
Speak directly with our metallurgical team for application-specific guidance and a no-obligation quote.
Military inspection system standard ensuring rigorous quality control.
Nuclear quality assurance certification for commercial nuclear components.
Military quality program standard for precision manufacturing compliance.
Share your specifications with our team and we'll respond with a detailed forging assessment and competitive quote. Whether you need standard aluminum bar profiles or fully custom closed-die forgings, MTS Forge is ready to deliver.
For immediate assistance, feel free to give us a direct call at (610) 857-3500. You can also send us a quick email at Fmicale@mtsforgepa.com
For immediate assistance, feel free to give us a direct call at (610) 857-3500. You can also send us a quick email at Fmicale@mtsforgepa.com