Forging Capabilities at Sypris Technologies

At Sypris Technologies, forging is a core competency backed by decades of process refinement and production-scale expertise. Our operations are optimized for high-volume, mission-critical components where mechanical integrity, fatigue resistance, and dimensional stability are non-negotiable. With vertically integrated capabilities and robust quality systems, we deliver precision-forged products that meet the stringent performance and compliance standards of OEMs across multiple sectors.

Closed-Die Forging Expertise

Sypris specializes in impression die (closed-die) forging using horizontal mechanical presses ranging from 1,600 to 4,000 tons. Our tooling and die designs are developed in-house using advanced FEA simulation and material flow analysis, allowing us to validate geometry, reduce development cycles, and ensure consistent forge fill and grain flow alignment.

Key process capabilities:

  • Closed-die impression forging with high die life performance
  • High-tonnage mechanical presses for complex geometries and high-strength materials
  • Automated billet handling and integrated heating systems for process repeatability
  • Net and near-net forging to minimize downstream machining
  • In-line and post-process heat treatment (normalize, quench & temper) for targeted mechanical properties

Product Portfolio

We support high-load, high-duty-cycle applications where component failure is not an option. Typical forged components include:

  • Axle beams and spindles
  • Suspension arms and brackets
  • Couplings, yokes, and transmission flanges
  • Drive train and power transfer elements
  • Structural supports and heavy mechanical links

All components are engineered to withstand extreme operational conditions and meet specific tensile, yield, and impact requirements.

Metallurgical Control

Material integrity is ensured through rigorous upstream and downstream controls. We process a wide range of carbon, alloy, and microalloy steels, with full traceability from melt source to finished component.

Metallurgical capabilities include:

  • Material spec verification and lot traceability
  • In-house mechanical testing (tensile, impact, hardness)
  • Microstructure and grain flow analysis
  • Heat treat process monitoring with continuous data logging (AMS 2750 compliance)

Integrated Quality Systems

Our facilities are certified to ISO 9001:2015, IATF 16949, and AS9100D, supporting automotive, commercial vehicle, and aerospace-level quality expectations. Quality is embedded at the source via:

  • In-process inspection and closed-loop SPC
  • High-resolution dimensional metrology (CMM, laser scanning)
  • Real-time process monitoring and part traceability
  • Root cause analysis and PFMEA methodology for issue resolution

Industry Alignment

We are a strategic partner to Tier 1 and OEM manufacturers in sectors where failure modes must be preemptively mitigated through process discipline and material performance. Our forged components are deployed globally across:

  • Heavy-duty transportation (Class 8, trailer, and off-road)
  • Energy & petrochemical (frac pumps, field equipment)
  • Agriculture and construction (power transmission and support structures)
  • Military applications (armor-grade and drivetrain components)