Manufacturing Processes
There are essentially three types of manufacturing processes used in the manufacture of aluminum wheels. Forging is an excellent technique for making aluminum wheels and involves the compression of a solid piece of aluminum, or billet, into the desired wheel design. This process results in an extremely strong and durable wheel. With rolled forging, aluminum sheets are rolled through heavy press wheels which imprint or stamp the aluminum with the wheel design. This process uses less aluminum than normal forging. Casting utilizes melted aluminum and is either poured or drawn into molds of the desired wheel design. The poured method is referred to as low-pressure casting while the drawn method is referred to as counter pressure.
Why Aluminum Is a Good Wheel ChoiceAs opposed to steel wheels, aluminum wheels are typically much stronger and have the ability to withstand more stress than steel wheels. Aluminum wheels are also easier to care for and will normally retain their original appearance better in the long run. Aluminum wheels also weigh less than their steel counterparts.Aluminum Wheel ConstructionTypically, aluminum and aluminum alloy wheels are manufactured in as either a single unit or one piece, or multiple unit which will consist of up to three separate aluminum pieces. A single-unit wheel is cast in a mold which includes all features of the wheel necessary for function.

BILLET WHEELS

​​How Cast Aluminum Wheels Are MadeRecommended Reading: How They Build It: Aluminum WheelsWhen it comes to after-market wheels, there are two common material options – steel wheels and aluminum wheels. While steel wheels are useful for dedicated off-road vehicles and heavy-duty trucks, aluminum wheels are a good option for almost all cars, trucks, and SUVs. Aluminum wheels are preferred for most consumer vehicles because:They’re lightweight. Heavy wheels reduce fuel economy, slow acceleration, and reduce suspension performance.They’re easy to mold and shape. It’s difficult to make complicated shapes with steel, but with Aluminum, wheel design is mostly limited by imagination.They’re very corrosion resistant.Ready for more details? There are three different ways you can build an aluminum wheel:Machining solid blocks of aluminum. Rarely will you find a wheel that’s completely machined, but you will often find a wheel with machined components. Machining is the only way to ensure precise fit, and a solid block of either forged or cast aluminum can be machined.Casting aluminum wheels from molten metal.  the cheapest way to go, but it’s not the best. Casting creates an imperfect metallic structure, which means cast aluminum wheels are weaker and more brittle than forged aluminum wheels.Forging aluminum wheels. Forged wheels are the best in terms of strength and weight, but they can be very, very expensive.