Blog

Are forged wheels lighter than cast wheels?

Weight Comparison and Manufacturing Process Differences Between Forged and Cast Wheels

Manufacturing Process Differences

Forged wheels and cast wheels differ fundamentally in their manufacturing processes, which directly affects their weight and performance:

• Cast Wheels: These are made using the gravity casting method, where molten aluminum is poured into a mold and cooled to form shape. This process is simple and low-cost, but it is prone to issues like air bubbles and uneven density, requiring more material to ensure sufficient strength.
• Forged Wheels: Forged wheels are produced by subjecting heated and softened aluminum billets to high-pressure impact inside a steel mold. This forging process results in a more uniform and dense molecular structure, allowing for less material to be used while still maintaining strength.

5×120 customized alloy car rims forged wheels (1)

Weight Comparison Data

According to professional evaluations and actual measurements, forged wheels clearly have a weight advantage:

• Weight Difference: Forged wheels are typically 10–20% lighter than cast wheels of the same size.
• Specific Example: For 18-inch wheels, measurements show that cast wheels weigh about 11.2 kg, while forged wheels weigh only 8.5 kg—a difference of 2.7 kg.
• Performance Impact: Reducing unsprung mass by 1 kg is roughly equivalent to reducing the vehicle body weight by 15 kg. The lighter weight of forged wheels significantly improves acceleration, braking response, and suspension agility.

Professional Evaluation

Multiple professional sources confirm the weight advantage of forged wheels:

• The forging process achieves a denser molecular structure through high-pressure impact, enabling lightweight strength.
• For the same size and strength requirements, forged wheels are noticeably lighter than cast wheels, which greatly enhances vehicle handling and fuel economy.
• Although cast wheels can also increase internal density by applying pressure, forged wheels still hold a significant weight advantage.

Kovani alu felge 18 19 20 21 22 5×112

Zaključak

Considering the manufacturing process, actual measurements, and professional evaluations, forged wheels are indeed lighter than cast wheels, typically by about 10–20%. This weight difference is mainly due to the forging process creating a denser molecular structure, allowing for less material to be used while maintaining strength. For those seeking high performance and the ultimate driving experience, forged wheels are the superior choice.