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.
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. (MTS Forge) in 1986 alongside Edward Waddell, driven by a shared vision to deliver high-quality forged solutions to America's most demanding industries. With a strong metallurgical background and extensive hands-on knowledge of forging practices, Stephen has been instrumental in shaping MTS Forge's technical capabilities and quality culture. Under his leadership, the company developed robust Quality Assurance Programs compliant with Mil I 45208 and NCA 3800, enabling MTS Forge to serve commercial nuclear, defense, aerospace, and power generation clients. His commitment to precision, traceability, and craftsmanship continues to define the standard for every carbon steel forged flange that leaves the Coatesville, PA facility.
Co-Founder
Edward Waddell co-founded MTS Forge in 1986, bringing a strong metallurgical background and a wealth of forging knowledge that has guided the company's growth over nearly four decades. Edward played a foundational role in establishing the principles of quality and service that remain central to MTS Forge's identity today. His technical expertise spans a wide range of forging processes and materials, enabling MTS Forge to serve industries from commercial nuclear and defense to power generation and chemical processing. Edward's vision helped build a facility in Coatesville, PA capable of delivering carbon steel forged flanges, special forgings, and custom components with the precision and traceability that critical industry sectors demand.
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.