Difference between Forged and Cast Wheels, and Why Bullite Prefers Forged

You’re thinking about driving ATVs or building your own racing car. Where do you start? Well, you have to have wheels— which might be a no brainer. But where to start? What kind of wheels do you need to look for, what is the price range you should be thinking about, what are the differences between forged and cast— the list can go on. In this blog series, we will be exploring those very questions, and at the very start, we can start with the basics-- what is the difference between forged and cast wheels?

Cast Wheels

The casting process involves pouring or using a vacuum to insert molten aluminum into a mold that is formed into the shape of a wheel. They can include positive pressure, that is used to move the aluminum into the mold more quickly, which achieves a product that has a greater density than a gravity cast wheel. After allowing time to cool , the mold is modified and adjusted to become made into the wheel, such as trimming or drilling. This is a process that is favored by most companies, as it is inexpensive, fast, and efficient. 

This process allows the wheel to maintain strength, have a lighter weight, and inexpensive cost to create. However, there poses to be many disadvantages of this method. Because of the molten aluminum creating inconsistencies in the wheel, it can introduce cracking and oxidation in the wheel. This ultimately compromises the wheels integrity, increasing chances of the wheel to crack and break during racing. This is why Bullite does not use this method, and we opp for the better process— Forged Wheels.

Forged Wheels

Forged wheels begin as a solid piece of metal that is then exposed to heat and intense pressure to compress the material, allowing the material to be condensed and impacted with that pressure. This material is then shaped into the wheel design, rather than trimmed and drilled into the intended shape. 

Contrast to casting, the forged wheels begins as a solid piece of metal known as the “billet”. With the intense heat and pressure, it compresses the material to form a raw forging, which allows the creation of different wheels design without adjusting or compromising its integrity.

While it is more time-consuming and therefore expensive, it is the preferred method that Bullite uses. It is much less porous than cast wheels, making the wheels more stronger and durable. The wheels structural integrity is not compromised, and allows for greater overall vehicle performance and enhance fuel efficiency. Especially during races such as the King of the Hammers, we pride ourselves on sacrificing efficiency and inexpensive materials to maintain quality over quantity, all at an affordable price.