- C1/503-504 Celebration City Center, Gala gymkhana road, South Bopal Ahmedabad, Gujarat, INDIA
Forging Manufacturer in India: Heavy Open Die Forgings up to 30 Tonnes
Sharma Technocast is an ISO 9001:2015 certified forging manufacturer in India. Our forging facility produces heavy open die and press forgings up to 30 tonnes single piece: shafts up to Ø 1,500 mm and 15,000 mm long, and rings, flanges, gear blanks and tube sheets up to Ø 3,000 mm, on 5,000-ton and 1,500-ton hydraulic forging presses with manipulators. Smaller parts are made by closed die, hammer and roll forging on drop hammer lines, a steam hammer and a screw press. Every forging is heat-treated, tested and, where required, finish-machined before dispatch, in carbon, alloy and stainless steels for power, oil & gas, steel, cement, mining, railway, shipbuilding and heavy-engineering OEMs worldwide.
Our Forging Facility
Forging Capabilities at a Glance
Open die, closed die and roll forging under one roof, up to 30 tonnes single piece, with heat treatment, testing and finish machining.
| Process | Equipment | Max size / weight | Best for |
|---|---|---|---|
| Heavy open die forging | 5,000 T hydraulic forging press, 30 t-m manipulator | Up to 30 t; round shafts Ø 1,500 × 15,000 mm | Shafts, rolls, rotors, rams, blocks |
| Medium press forging | 1,500 T and 1,250 T hydraulic presses, 10 t-m manipulator | Medium-weight forgings | Step shafts, hubs, couplings, spindles |
| Hammer forging | 10 MT steam hammer, 6 T pneumatic hammer line | On request | Free-forged shafts, flanges, blocks |
| Closed die forging | 1.5–4.5 T drop hammer lines, screw press line, in-house die shop | On request | Near-net-shape parts in volume: crankshafts, axle parts, gear blanks |
| Roll forging | Roll forging line | On request | Shafts, tapered parts, axle beams, gear blanks |
| Rings, discs & flanges | Upset and press forging | Up to Ø 3,000 mm; rings and flanges up to 20 t, discs up to 30 t | Rings, non-standard flanges, gear blanks, tube sheets, crane wheels |
| Hollow & rectangular forgings | 5,000 T / 1,500 T presses | Hollow OD 1,500 / ID 1,000 × 10,000 mm; sections 1,500 × 12,000 mm; up to 30 t | Hollow shafts, bushes, blocks, cross heads |
| Heating & heat treatment | Gas-fired furnaces up to 1,400 °C, bogie heat-treatment furnaces, polymer and oil quench tanks | Furnace 4 × 2.5 × 9 m, 50 t; quench tanks 2.5 × 3.5 × 9 m | Normalising, annealing, quenching & tempering |
| Finish machining | 20 CNC lathes, 8 HMCs, vertical boring, 7 cylindrical grinders | Turning Ø 1,200 × 10,000 mm; vertical boring Ø 5,000 mm | Proof-machined or ready-to-fit forgings |
Need a forging outside these ranges? Send your drawing and we will confirm feasibility within 24–48 hours.
Send Your RFQAdvanced Heat Treatment & Material Performance
We enhance the mechanical properties and durability of every forged component through precise heat treatment:
This ensures structural stability, wear resistance, and optimized performance in downstream CNC machining and industrial applications.
Forged Components We Manufacture
Materials & Grades We Forge
We forge carbon, alloy, and stainless steels to EN, AISI, ASTM, SAE and IS standards, including grades such as EN8, EN19, EN24, AISI 4130, 4140 and 4340, ASTM A105, A350 LF2 and A182 F-series (F11, F22, F304, F316), plus hot die steels. Forgings are supplied as rough-forged, proof-machined or fully finished, as round bars, flat bars, discs, rings or complex shapes.
- Full traceability: every forging is marked with its heat number and supplied with material test certificates
- Your specification: customer-specified grades and international equivalents forged on request
Our material selection ensures strength, fatigue resistance, and long-term reliability across power, oil & gas, railway, mining and heavy engineering industries.
Quality & Testing
Every batch is heat-treated and tested before dispatch, with full material traceability:
- Ultrasonic Testing (UT)
- Magnetic Particle Inspection (MPI)
- Dye Penetrant Testing (DPT)
- Tensile, Impact & Brinell Hardness Testing
- Microstructure Analysis
- Chemical Analysis for Every Heat
Our in-house gas-fired heat treatment furnaces (up to 50 t) with polymer and oil quench tanks deliver normalising, annealing, quenching and tempering to meet your specified mechanical properties.
Engineering & Die Design
We deliver complete engineering support through:
Our team ensures design feasibility, performance optimization, and cost-effectiveness for every forged component.
Types of Forging
We offer a comprehensive range of industrial forging services designed to meet diverse application needs. Whether you require near-net shape forgings for the automotive sector or large open-die forged components for heavy engineering, we ensure precision, durability, and superior performance in every product.
Each route suits a different combination of size, volume and tolerance. The full forging process, including the steps involved and where defects originate, is covered separately.
Open Die Forging
Open die forging is a flexible and robust metal shaping process that transforms raw materials into precision-engineered components. Commonly used for large, custom shapes, this method enhances metal grain structure, improves mechanical properties, and ensures dimensional integrity. Ideal for low-volume production, aerospace applications, and heavy machinery components, open die forging offers superior strength and versatility
Read the full open die forging guide →
Closed Die Forging
Also known as impression-die forging, closed die forging is ideal for producing high-strength, high-precision components with complex geometries. Widely used in automotive, aerospace, and energy sectors, this method provides tight tolerances, improved grain flow, and repeatable near-net-shape production. It is the preferred solution for applications requiring maximum strength, accuracy, and reliability.
Read the full closed die forging guide →
Roll Forging
Roll forging is a continuous forging process where metal billets are compressed between rotating rolls to create uniform and durable shapes. Perfect for shafts, tapered parts, and gear blanks, roll forging enhances metal strength, reduces material waste, and is highly suitable for high-volume production in railways, construction equipment, and automotive industries.
Read the full roll forging guide →
Proven Track Record
With 15+ years of group experience in metal manufacturing, Sharma Technocast has delivered forged components to clients across India and worldwide. Our projects reflect a commitment to quality and practical engineering, establishing us as a trusted forging manufacturer in Ahmedabad, India.
Testing Equipment & Documents
Sharma Technocast is ISO 9001:2015 certified (accredited and verifiable on IAF CertSearch). Every batch is heat-treated and tested before dispatch, and we welcome third-party inspection by your nominated agency.
| Certification | ISO 9001:2015 Quality Management System |
|---|---|
| Non-destructive testing | Ultrasonic flaw detection (4 × Modsonic Einstein-II DGS), magnetic particle testing, dye penetrant testing |
| Mechanical testing | Digital universal testing machine (200 kN, Krystal Elmec), impact testing (KI-300), optical Brinell hardness testing (KB-3000) |
| Metallurgical & dimensional | Inverted metallurgical microscope with image analysis, profile projector |
| Chemical analysis | For every heat, to the specified grade |
| Heat treatment | Gas-fired bogie furnaces up to 50 t and 1,200 °C, polymer and oil quench tanks (2.5 × 3.5 × 9 m) |
| Documents supplied | Material test certificates, UT and NDT reports, heat treatment charts, dimensional reports |
Why Choose Sharma Technocast for Forging?
Sharma Technocast delivers high-strength forging solutions engineered for durability, dimensional accuracy, and long-term performance. Recognized as a leading forging manufacturer in Ahmedabad, India, we combine advanced forging technologies with strict quality control to produce reliable forged components. Our solutions are trusted by automotive, industrial, construction, and engineering industries across India and worldwide.
Request a Quote
Ready to get started? Contact us today to discuss your project.
Our Experts Answers
Frequently Asked Questions
Forging is the shaping of hot or cold metal by hammering or pressing it under high force. Unlike casting, the metal never melts, so its grain flow follows the shape of the part, giving forgings higher strength, toughness and fatigue resistance than cast or fully machined parts.
Open die forging shapes metal between flat or simple dies, so it suits large parts and low volumes such as shafts, discs and blocks. Closed die forging presses metal into a shaped die cavity, giving near-net-shape parts with closer tolerances, and is more economical for repeat volumes.
Roll forging passes a heated bar between rotating rolls with shaped grooves, reducing its section and increasing its length in steps. It is used for shafts, tapered parts, axle beams and gear blanks, and gives a continuous grain flow along the part.
We make single-piece forgings up to 30 tonnes: round shafts up to Ø 1,500 mm and 15,000 mm long, square and rectangular sections up to 1,500 mm and 12,000 mm long, hollow shafts up to OD 1,500 / ID 1,000 mm, and rings, flanges and gear blanks up to Ø 3,000 mm, on 5,000-ton and 1,500-ton hydraulic forging presses. Smaller parts are made by closed die, hammer and roll forging on our 1,250-ton press, 10 MT steam hammer, 6 T pneumatic hammer, 1.5–4.5 T drop hammers and screw press.
We forge carbon, alloy and stainless steels to EN, AISI, ASTM, SAE and IS standards, including grades such as EN8, EN19, EN24, AISI 4130, 4140 and 4340, ASTM A105, A350 LF2 and A182 F-series.
Yes, in most cases. Forging refines the grain and removes the porosity that casting can leave, so forged parts usually have higher tensile strength, impact toughness and fatigue life. Casting is better for very complex shapes or hollow parts. We make both, so we can recommend the right route for your part.
Every forging is heat-treated and tested: ultrasonic flaw detection, magnetic particle and dye penetrant testing, tensile testing on a 200 kN universal testing machine, impact and Brinell hardness testing, microstructure examination and chemical analysis for every batch. Shipments include material test certificates, UT/NDT reports and dimensional reports.
No fixed minimum. Open die forging suits single pieces and small batches. Closed die forging needs a die, so it becomes economical for repeat volumes. We recommend the most economical route for your quantity.
Typical lead time is 4 to 6 weeks from drawing approval, depending on size, material, die requirements, heat treatment and machining. We confirm a firm schedule with every quotation.
How do I request a quote for forgings?
Send your drawing (PDF, STEP or IGES), material grade, quantity, heat treatment and testing requirements and target delivery date through our RFQ form or to [email protected]. We usually reply within 24–48 hours.