Precision-engineered custom metal parts for global OEMs. From prototype to high-volume production — forging, casting, CNC machining and more.
From precision investment casting to high-volume CNC machining, we deliver custom metal components that meet the most demanding specifications. Explore all capabilities →
Near-net-shape parts with superior surface finish and tight tolerances.
Learn MoreAluminum, zinc & magnesium for complex, high-volume designs.
Learn MoreCost-effective solution for medium-to-high volume metal components.
Learn MoreTight tolerances and repeatable quality for precision-critical parts.
Learn MoreHot & cold forging, open die, drop forging for maximum strength.
Learn MoreSingle, multi-spindle, Swiss and CNC screw machining services.
Learn MoreHigh-volume custom fasteners, screws, bolts, nuts and more.
Learn MoreCustom steel, aluminum and brass profiles for any application.
Learn MoreEvery project follows a proven four-stage process designed to deliver precision parts on time, on spec, and within budget.
Over 40 years of design-for-manufacturability expertise. We optimize your designs to reduce cost without sacrificing performance.
Learn MoreCastings, forgings, metal fabrication and precision machining — executed through our global certified manufacturing network.
Learn MoreISO 9001:2015 certified processes. Every component is inspected to ensure it meets your exact print requirements — zero compromise.
Learn MoreStreamlined supply chain management from factory floor to your dock. We handle the complexity so you don't have to.
Learn MoreOur engineering and manufacturing experts have decades of experience creating precision metal products for aerospace, automotive, medical, agriculture, construction, and industrial applications worldwide.
View ProductsGlobal brands that rely on TFG USA for precision metal manufacturing solutions.
At The Federal Group USA, our on-the-ground engineers direct machining processes and inspect tooling at every stage of the supply chain. We don't just ship parts — we certify them.
Our ISO 9001:2015 Quality Management System, certified by NSF International, is under continuous improvement to satisfy our customers' ever-evolving requirements. Every component is built-to-print, every time.
Expert knowledge on metal manufacturing processes, industry trends, and engineering best practices from the TFG USA team.
CNC Machining Choosing the right CNC machining process depends on more than the material or dimensions of a part. The number of axes determines complexity, tolerances, and cost.
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Metal Forging When components need exceptional strength, tight dimensional tolerances, and long service life, closed die forging is one of the most reliable manufacturing processes available.
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Die Casting Understanding the difference between metal injection molding vs die casting requires looking at the physical state of raw material, production volumes, and tolerance requirements.
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Die Casting Choosing the right aluminum alloy is critical to the success of any die casting project. The material you select affects strength, corrosion resistance, and machinability.
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Metal Forging Stainless steel forging produces components that are stronger, denser, and more fatigue resistant than cast alternatives. Discover the key process considerations.
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Sand Casting Designing a part for sand casting requires more than creating a moldable shape. Decisions like wall thickness and draft angles directly impact quality and cost.
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Case Study An in-depth analysis of hole position tolerance for a handlebar weldment. Our engineering team conducted a full manufacturing and inspection review, confirming 100% of parts met drawing requirements — and provided actionable recommendations for the mating assembly fit.
This case study demonstrates our commitment to transparency, precision, and collaborative problem-solving at every stage of the supply chain.
Trusted by procurement professionals and engineers across North America and beyond.
"The Federal Group has demonstrated professionalism, responsiveness, and a willingness to collaborate. Communication has been timely, and they've shown a true commitment to understanding our requirements. Competitive pricing, good quality, and a cooperative approach to resolving issues. Alanna and Sandor are amazing!"
"Mike Allen and The Federal Group have been an absolute pleasure to work with. From day one they responded punctually and professionally, helping us through every step. We came with a budget-conscious challenge and they delivered above and beyond — a quality finished part that improved our overall product. Thank you!"
"Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product in a timely manner. We've sent all our casted parts through them — best service, every step."
Our engineering team is ready to review your project requirements, provide process recommendations, and deliver a competitive solution tailored to your needs.