Full-Service OEM Metal Component Manufacturing
With over 40 years of specialized manufacturing experience, The Federal Group USA delivers end-to-end custom metal solutions. From initial Design for Manufacturability (DFM) consultation and prototype tooling to high-volume production, surface treatment, and global logistical fulfillment, we provide international buyers with uncompromised quality and certified precision.
Core Metal Manufacturing Capabilities
Explore our full range of custom metalworking capabilities engineered to meet strict ASTM, DIN, ISO, and SAE standards for global industrial applications.
Metal Casting Services
High Precision & Complex GeometriesDie Casting Solutions
High-pressure aluminum, zinc, and magnesium die casting for high-volume, thin-walled components requiring precise tolerances and clean surface finishes.
- Materials: A380, ADC12, Zamak 3/5
- Tolerance: ± 0.002 in (0.05 mm)
- Volume: 5,000 – 1,000,000+ pcs
Investment Casting (Lost Wax)
Ideal for intricate near-net-shape metal parts with superior surface smoothness, minimal machining needs, and complex internal passages.
- Materials: Stainless Steel, Carbon Steel, Alloy Steel
- Surface Finish: Ra 3.2 – 6.3 µm
- Application: Valves, Pumps, Medical & Aerospace
Sand Casting & Mold Casting
Cost-effective production for medium-to-large heavy industrial components, heavy machinery housings, and iron/steel structural castings.
- Materials: Ductile Iron, Gray Iron, Cast Steel
- Weight Range: Up to 5,000 lbs (2,200 kg)
- Advantage: Low Tooling Cost
Forging & Cold Forming
Maximum Tensile & Fatigue StrengthHot & Closed Die Forging
Produces dense, high-strength structural parts with continuous grain flow for load-bearing automotive, agricultural, and construction equipment parts.
- Materials: Carbon Steel, Alloy Steel, Stainless
- Process: Closed Die / Drop Forging
- Standards: ASTM, DIN EN 10254
Cold Heading & Cold Forming
High-speed, zero-waste process for custom industrial fasteners, shoulder bolts, rivets, shafts, and custom cold-formed tubular components.
- Production Speed: Up to 300 PPM
- Material Savings: Up to 70% vs. CNC
- Size Range: M3 – M24 Custom Specs
Open Die Forging
Engineered for large steel rings, heavy shafts, seamless forged sleeves, and custom industrial shapes where extreme mechanical strength is mandatory.
- Capacity: Heavy-duty Industrial Scale
- Testing: Ultrasonic & MPI Inspection
- Application: Power Gen, Mining, Marine
CNC Machining & Fabrication
Micron Tighter Tolerances3, 4 & 5-Axis CNC Milling & Turning
High-precision machining centers equipped for multi-axis milling, turning, boring, and tapping of critical aerospace, energy, and automotive components.
- Tight Tolerance: ± 0.0005 in (0.012 mm)
- Machining: Aluminum, Brass, Titanium, Inconel
- Inspection: Zeiss 3D CMM Verification
Swiss Screw Machining
High-precision turning for intricate, micro-diameter cylindrical components used in medical devices, electronics, optical assemblies, and precision hardware.
- Diameter Range: 0.5 mm to 32 mm
- Precision: Ultra-fine Micro Specs
- Volume: Medium to High-Volume Runs
Sheet Metal Fabrication & Extrusions
Precision fiber laser cutting, CNC brake bending, custom aluminum profile extrusions, metal stamping, and complete mechanical sub-assemblies.
- Laser Cutting: Up to 25 mm Steel Thickness
- Extrusions: Custom 6000-series Aluminum
- Finishing: Powder Coating, Anodizing, Plating
Why Overseas Procurement Leaders Trust TFG USA
We eliminate cross-border quality risks through US-managed engineering oversight, ISO 9001 quality management, and transparent supply chain reporting.
ISO 9001:2015 Certification
Certified by NSF International. Every manufacturing unit adheres to audited Quality Management Systems ensuring zero defect production.
Full Material Traceability
100% material chemical analysis and mechanical testing reports (MTR EN 10204 3.1) provided with every production shipment.
On-Site Quality Engineers
Our dedicated bilingual quality engineers audit tooling, supervise first-article inspections (FAIR/PPAP Level 3), and manage pre-shipment checks.
Global DDP / FOB Freight
We handle all customs clearance, international duty compliance, and ocean/air logistics, delivering direct to your manufacturing plant dock.
Frequently Asked Questions for Global Procurement
Key information to help sourcing managers, technical engineers, and supply managers evaluate our capabilities.
What metal manufacturing capabilities does TFG USA specialize in?
TFG USA offers a comprehensive range of custom metal manufacturing capabilities including high-pressure die casting, investment casting, sand casting, 3/4/5-axis CNC machining, hot and cold metal forging, metal injection molding (MIM), aluminum and brass extrusions, and sheet metal fabrication.
How do you ensure cross-border product quality and tolerance compliance?
We maintain strict ISO 9001:2015 processes. All initial samples undergo First Article Inspection Reports (FAIR) and PPAP documentation using 3D CMM inspection tools. Production lots undergo 100% critical dimension checks and material spectrographic testing before export shipping.
What engineering files do you accept for custom manufacturing quotes?
We accept standard industrial 3D CAD files including STEP (.stp), IGES (.igs), SolidWorks (.sldprt), as well as 2D PDF drawings containing GD&T specs, surface treatment details, and material callouts. Our engineering team conducts DFM reviews for all requests.
What international shipping and Incoterms options do you support?
We offer flexible shipping terms designed for global OEM supply chains, including FOB, CIF, DDP (Delivered Duty Paid to door), and Vendor-Managed Inventory (VMI) setups. We handle all export customs packaging, palletizing, and shipping documentation.
Need Custom Metal Components Manufactured to Print?
Our engineering and global sourcing experts are online and ready to evaluate your CAD models, supply technical specifications, and provide transparent DFM feedback.
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