Custom Forged Wheels Manufacturing

Custom Forged Wheels Manufacturing

A forged wheel starts as a single billet of 6061-T6 aluminium alloy, compressed under roughly 10,000 tonnes of force until its grain structure aligns in one direction. The result is a wheel that weighs approximately 30% less than an equivalent cast piece while handling significantly higher stress loads. For any car where unsprung mass matters — and that is every car — the difference is measurable in braking distances, turn-in response, and ride quality.

Hodoor manufactures custom forged wheels to individual order. There is no minimum batch, no catalogue you have to choose from, and no compromise between what you want and what happens to be in stock.

How the Process Works

1. Design and Specification

Every project begins with a conversation. You tell us the car, the intended use, and the look you are after. We discuss diameter, width, offset, bolt pattern, and finish — then produce a technical drawing for your approval. If you already have a design in mind, we work from your reference. If you want something original, our AI design system can generate over 1,000 unique concepts in a single day, or our in-house designer can sketch options from scratch.

2. Forging and Machining

Once the design is signed off, production begins. The aluminium billet is heated and pressed in a closed-die forging operation, then CNC-machined to final dimensions. Tolerances are held to within 0.05 mm. Each wheel is individually balanced and inspected before leaving the facility. Typical production time is four to eight weeks from design approval.

3. Surface Finishing

Available finishes include gloss black, matte black, brushed titanium, polished aluminium, and custom RAL colour matching. Ceramic clear coat is applied as standard to protect against brake dust, road salt, and UV degradation.

What You Get

• Material: 6061-T6 forged aluminium — the same alloy used in aerospace and motorsport applications
• Weight reduction: approximately 30% lighter than cast equivalents of the same size
• Fitment: manufactured to your car's exact bolt pattern, centre bore, offset, and diameter
• Certification: TUV and JWL load-rated where applicable
• Warranty: structural warranty against manufacturing defects

Who This Is For

Most of our clients fall into one of three categories: owners of performance cars who want lighter wheels without sacrificing strength, owners of luxury SUVs who want a unique design that sets their vehicle apart, and owners of electric vehicles looking to reduce unsprung mass for improved range and handling. We have manufactured wheels for over 200 different vehicle platforms, from a Porsche 911 GT3 to a Mercedes-AMG G63 to a BMW iX.

Frequently Asked Questions

How long does production take?
Four to eight weeks from design approval to delivery, depending on complexity and finish.

Can you match a specific design or brand style?
Yes. We can reproduce the visual character of any reference design while engineering the wheel to your car's specific fitment requirements.

Do you ship internationally?
We deliver to over 40 countries. Wheels are shipped in individual protective packaging with full insurance coverage.

What is the minimum order?
One wheel. Most clients order sets of four, but single replacements and staggered setups are equally straightforward.

To start a project, contact us at [email protected] with your car model, desired size, and any design references. We respond within one business day.