Cast? FlowForm? Forged? ...?

Wheel manufacturing overview

1. Cast wheels (Low Pressure Casting)

Most common

Process
Molten aluminum is poured into a mold.

Advantages

• Affordable
• High design flexibility
• Suitable for daily use

Disadvantages

• Less strong
• Heavier
• Risk of porosity

Conclusion
Best for OEM and budget

2. Flow Forming (Flow Forged or Rotary Forged)

Mid range solution

Process
Wheel is cast then the barrel is stretched under pressure.

Advantages

• Lighter
• Stronger (especially the barrel)
• Improved structure

Disadvantages

• Not as strong as forged
• Partial reinforcement only

Conclusion
Best price performance balance

3. Forged wheels

High end

Process
Solid aluminum block compressed under high pressure then CNC machined.

Advantages

• Extremely strong
• Very light
• High density

Disadvantages

• Expensive
• Less design freedom

Conclusion
Performance and motorsport

Other processes

Gravity Casting
Simple and cheap
Less strong

High Pressure Casting
Fast production
Lower quality possible

Multi piece wheels
Built from multiple parts

Advantages

• Customizable
• Repairable

Disadvantages

• Expensive

Comparison

Type | Strength | Weight | Price | Use
Gravity | low | high | low | budget
Low pressure | medium | medium | medium | daily
Flow forming | high | low | mid high | sport
Forged | very high | very low | high | performance