U.S. Metal Forging Market Size & Share Analysis - Trends, Drivers, Competitive Landscape, and Forecasts (2025 - 2032)

U.S. Metal Forging Market Growth Factors

integration of Advanced Technologies Is a Key Trend

• The usage of CAD, CAM, and CAE raises business profitability by quickening up projects, helping create better designs for end products, and reduce human errors.
• CAE tools, such as finite element analysis (FEA), computational fluid dynamics (CFD), and simulation, enable companies to design, test, and optimize forged components virtually, before mass production.
• AI-integrated CAE platforms can control processing parameters in real time to improve quality and keep production consistent.
• With the growing demand for lightweight, strong, precise, and durable components in the aerospace, automotive, and energy sectors, the combination of CAE, CAD, and CAM is being used to produce high-performance forged components at lower costs.
• The advent of 3D printing is revolutionizing metal forging by helping create parts complex in design and functionalities and reducing waste.
• The deposition of molten metal in layers in the additive manufacturing process offers limitless possibilities in terms of creating complex designs.
• The fact that the entire end product would be one component, instead of a system of different components bolted or welded together, further enhances structural integrity.
• The automotive and aerospace industries have already adopted 3D metallic printing on a large scale for prototyping and mass production of various components.

Increasing Adoption in Automotive Industry Drives Market

• A major driver for the growth of the market is the rising demand for lighter, stronger, and more-durable automotive components.
• The transition to EVs increases the need for stronger forged parts, including in motors to offer higher torque.
• The growth of automotive manufacturing in the U.S. is supported by federal incentives and reshoring efforts.
• Automobile sales continue to grow due to the rising demand for personal, public, and freight transportation, supported by an extensive road network in the country.
• As per the Federal Reserve Bank of St. Louis, vehicle sales in the U.S. increased from 192.122 million units in 2023 to 195.434 units in 2025.
• Metals are the primary building blocks of automobiles, being the main raw material not just for their superstructure but also other critical components, such as engines, transmissions, gearboxes, control pedals, gear sticks, and chassis.
• As per studies, up to 75% of a vehicle’s weight is attributed to metallic components and parts.
• To offer a longer service life and higher durability, stronger metal components are being used.

U.S. Metal Forging Market Segmentation Analysis

Raw Material Analysis

The carbon steel category held the largest market share, of 70%, in 2024. This is because of its strength, cost, and versatility, which give it priority in the automobile, construction, shipbuilding and industrial machinery sectors. Moreover, its ease of forging, heat treatment, and machining drive the demand for it. Another reason for its high popularity it is recyclability, which fits into the sustainability approach of the country.

The titanium category will grow at the highest CAGR during the forecast period. This is because of the rising demand for titanium in the aerospace, defense, and medical sectors due to its high strength-to-weight ratio, corrosion resistance, and high-temperature performance. These properties make it ideal for jet engine components, military equipment, and surgical implants. This category is driven by the technological advances in forging aimed at making the process cheaper and investments in next-generation aircraft and military systems.

The raw materials analyzed in this report are:

• Carbon Steel (Largest Category)
• Alloy Steel
  • Nickel Alloys
  • Chromium Alloys
  • Molybdenum Alloys
• Stainless Steel (Fastest-Growing Category)
  • Aluminum
  • Magnesium
  • Titanium
• Others

Technology Analysis

The closed-die category held the largest market share, of 60%, in 2024, because it is efficient in producing complicated, precise components in mass quantities. This near-net-shape application, with its high mechanical properties, is important for automotive, aerospace, and defense applications that require accuracy and strength.

The open-die category will grow at the highest CAGR during the forecast period The growing demand for large, customized components in renewable energy and infrastructure drives its usage in the manufacturing of wind turbine shafts and pressure vessels. Up to 450 tons can be handled by the open-die process, making it ideal for creating durable structural components.

The technologies analyzed in this report are:

• Closed Die (Largest Category)
  • Impression Die
  • Precision Die
• Open Die (Faster-Growing Category)
  • Upset Forging
  • Ring Rolling Forging
• Others

End Use Analysis

The automotive category held the larger market share, of 65%, in 2024. This is because of the criticality of metals for crankshafts, transmission gears, axle beams, chassis, and the outer shell. The forging process gives parts superior strength, fatigue resistance, and durability, all of which are essential for modern vehicles amidst the rising passenger safety concerns.

The end uses analyzed in this report are:

• Automotive (Largest Category)
  • Engine Components
  • Suspension Components
• Mechanical Equipment
  • Heavy Machinery Parts
  • Power Transmission Components
• Oil & Gas (Fastest-Growing Category)
  • Drilling Equipment Parts
  • Pipeline Components
• Aerospace
• Railways
  • Wheel Sets
  • Axles
• Agriculture
• Construction
• Others

U.S. Metal Forging Market Regional Outlook

The Midwest held the largest market share, of 40%, in 2024. Michigan, Ohio, and Illinois have long been the key hubs for heavy-duty manufacturing, leading to a consistent demand for forged metal products. These include crankshafts, gears, and axles for the automotive and machinery industries. It is close to the suppliers of steel and has a skilled workforce, with major forging companies, such as Scot Forge and Ellwood Group, operating there.

The South will grow at the highest CAGR during the forecast period, because of the investments in manufacturing facilities and infrastructure. This increases both the production capacity and demand for forged metals. The market is essentially driven by the expansion of the automotive, aerospace, and manufacturing industries due to the favorable business environment and lower operational costs.

The geographical breakdown of the market is as follows:

• Northeast
• West
• Midwest (Largest Category)
• South (Fastest-Growing Category)

U.S. Metal Forging Market Share

The market share is consolidated because of the presence of large players, including Scot Forge, Precision Castparts Corp. (PCC), Ellwood Group, and Alcoa. They hold major shares in various high-value sectors, such as aerospace, defense, and energy. They control prices and technologies, using advanced manufacturing, securing long-term contracts with OEMs, and achieving economies of scale.

U.S. Metal Forging Market News & Updates

• In April 2024, ELLWOOD announced plans to install a new 20-ton vacuum induction melting (VIM) at its New Castle, Pennsylvania facility. The investment will expand ELLWOOD's production capacity for high-quality specialty metals.
• In December 2023, Canton Drop Forge entered into a partnership with Weld Mold to better equip their employees with the necessary welding skills.