Closed Die Forging
Our closed die forging process shapes aluminum connecting rods to near-net form, minimizing raw material waste and machining costs while producing dense, directional grain flow for superior tensile strength and fatigue life.
When engine performance demands zero compromise, forged aluminum connecting rods deliver the strength, precision, and fatigue resistance that cast or billet parts simply cannot match. At MTS Forge, we apply decades of closed die forging expertise and metallurgical knowledge to produce connecting rods engineered to withstand extreme combustion loads, high RPM stress cycles, and the punishing demands of both racing and high-performance industrial engines.
From closed die forging to final rough machining, we deliver precision aluminum connecting rods built for demanding performance applications.
Our closed die forging process shapes aluminum connecting rods to near-net form, minimizing raw material waste and machining costs while producing dense, directional grain flow for superior tensile strength and fatigue life.
We produce connecting rods to exact customer specifications — from small high-revving racing applications to heavy-duty industrial engines — using cutting-edge tooling design and time-honored forging craftsmanship made in America.
Contour forging allows us to produce connecting rods with complex geometries and tight dimensional tolerances using a wide range of aluminum alloys, ensuring optimal strength-to-weight ratios for performance-critical applications.
In-house normalizing heat treatment refines grain structure in forged aluminum rods, relieving internal stresses introduced during forging and delivering uniform mechanical properties, improved toughness, and enhanced machinability throughout each component.
Post-forging rough machining brings connecting rods to near-net shape in-house, removing flash and surface irregularities to reduce your lead time, eliminate secondary vendor handling, and deliver parts closer to print-ready condition.
For connecting rod caps, pins, and bolt-flange geometries, our upset forging capability handles components up to 1,500 lbs and 26 inches in diameter, supporting full rod assembly component production under one roof.
We begin with a thorough review of your connecting rod drawings and performance requirements. Our in-house team designs and develops custom dies and tooling sized to your rod geometry, keeping tooling costs competitive and lead times tight from the very first step.
See how MTS Forge delivers precision forged aluminum connecting rods that perform under the most demanding conditions.
For nearly 40 years, MTS Forge has built a reputation on metallurgical expertise, in-house capabilities, and uncompromising quality — here is what sets us apart.
Founded by metallurgists, our team understands aluminum grain structure and fatigue mechanics at the material science level, not just the process level.
We design and build our own dies and tooling on-site, giving you competitive tooling costs and faster turnaround than shops relying on outside vendors.
Our documented Quality Assurance Program provides complete material and process traceability on every connecting rod, meeting aerospace and defense procurement standards.
Every connecting rod is forged, heat-treated, and rough-machined at our Coatesville, PA facility — no offshore sourcing, no supply chain surprises.
Led by founders with deep metallurgical roots and decades of forging industry experience.
Co-Founder
Stephen Carr co-founded Manufacturing & Technical Services, Inc. in 1986 alongside Edward Waddell, building MTS Forge from the ground up on two foundational principles: quality and service. With a strong metallurgical background and extensive hands-on knowledge of forging practices, Stephen has guided MTS Forge's technical direction for nearly four decades. His deep understanding of material behavior under compressive forming — including aluminum alloy selection, die design, and heat treatment metallurgy — directly informs how MTS Forge approaches demanding components like connecting rods. Under his leadership, the company invested in state-of-the-art forging equipment and developed an expert team capable of producing forgings for aerospace, defense, power generation, and high-performance automotive applications. Stephen's commitment to American manufacturing and metallurgical precision remains central to MTS Forge's identity today.
Co-Founder
Edward Waddell co-founded MTS Forge in 1986 with Stephen Carr, channeling his metallurgical expertise and forging industry knowledge into building one of Pennsylvania's respected precision forging manufacturers. Edward's background spans the full forging process — from billet preparation and die engineering through normalizing heat treatment and quality assurance — giving him a comprehensive view of what it takes to produce high-integrity forged components that perform reliably under stress. His focus on continuous improvement and investment in cutting-edge technology helped MTS Forge expand its product range to serve aerospace, defense, nuclear, and high-performance industrial markets. Edward's dedication to craftsmanship and material science excellence is reflected in every forged aluminum connecting rod that leaves the Coatesville, PA facility bearing the MTS Forge name.
Yes — forged connecting rods are significantly stronger than cast alternatives. The forging process aligns the aluminum's grain structure along the rod's primary stress axis, producing superior tensile strength, fatigue resistance, and impact toughness. Cast rods contain random grain orientation and porosity that can lead to premature failure under high-cycle loading. For any high-performance, racing, or heavy-duty engine application, forged rods are the engineering choice.
Our metallurgical experts are ready to help you specify the right rod for your application.
Military-grade inspection system certification for manufacturing quality assurance.
Nuclear quality assurance standard certification for safety-critical forged components.
Comprehensive military quality program standard governing production process controls.
Share your drawing, specifications, or performance requirements and our engineering team will respond with a detailed quote and recommended forging approach for your application.
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