Wind Turbine Forging Market By Component Type (Main Shaft, Rotor Hub, Flanges, Bearings & Gears, Others); By Forging Type (Open-Die Forging, Closed-Die Forging, Seamless Rolled Ring Forging); By Material (Carbon Steel, Alloy Steel, Others); By Geography, Segment Revenue Estimation, Forecast, 2024–2030.

1. Introduction and Strategic Context

The Global Wind Turbine Forging Market is projected to expand at a robust CAGR of 6.8% , rising from a value of around USD 8.6 billion in 2024 to reach approximately USD 12.9 billion by 2030 , according to Strategic Market Research.

 

This market sits at the intersection of heavy industrial manufacturing and clean energy transition. Forged components — particularly main shafts, flanges, gear blanks, and rotor hubs — are mission-critical for turbine stability and performance. Unlike cast or welded parts, forged components offer superior mechanical strength, making them indispensable in both onshore and offshore installations.

 

What's driving strategic interest? The shift toward larger turbines and harsher operating environments . Developers are moving toward 15MW+ turbines in offshore wind farms, requiring ultra-durable, fatigue-resistant components. That’s where forging plays a strategic role — especially closed-die and open-die processes using high-grade alloy steel.

 

Also, policy momentum is fueling demand. The U.S. Inflation Reduction Act, EU Green Deal, and China’s 14th Five-Year Plan all embed wind energy targets with clear procurement pipelines. And with most forged wind components still made in Asia or Europe, the market is seeing calls for localization and supply chain reshoring — especially in the U.S. and India.

 

OEMs like Vestas , Siemens Gamesa , GE Vernova , and Goldwind are now redesigning turbines with modular forged parts to reduce transportation bottlenecks. On the supplier side, companies like Bharat Forge, Thyssenkrupp , Frisa , and Jiangsu Pacific Precision Forging are doubling down on capacity and automation.

 

To be honest, forging was once seen as a background industrial process. But now, as turbines get taller and more remote, every bolt, shaft, and ring forged with precision is becoming a frontline enabler of global energy goals.

 

2. Market Segmentation and Forecast Scope

The wind turbine forging market splits across several key dimensions — each tied closely to how turbine designs are evolving and how manufacturers are optimizing for size, durability, and lifecycle cost.

Let’s break down the most relevant segmentation structure:

By Component Type

• Main Shaft This remains the largest segment in 2024, accounting for around 37% of total market revenue . These massive, high-load components connect the rotor hub to the gearbox or generator. Due to high torsional and bending loads, forged shafts are considered non-negotiable for structural integrity.

• Flanges Used to connect tower sections or nacelle components. Demand is rising especially for multi-piece turbine towers , where forged flanges offer better stress distribution than welded alternatives.

• Rotor Hubs Typically made from forged steel to withstand extreme offshore conditions. As rotor diameters exceed 150 meters, the mechanical performance of these parts becomes mission-critical.

• Bearings and Gears Growth here is tied to higher-capacity gearboxes and longer turbine lifecycles — both of which require forged blanks with tight tolerance and high fatigue resistance.

• Others Smaller forged parts such as bolts, rings, and couplings. While individually low-value, they add up in volume across multi-MW installations.

The fastest-growing segment? Rotor hubs — driven by offshore deployments and rising OEM preference for forging over casting in key drivetrain assemblies.

By Forging Type

• Open-Die Forging Dominates large parts like main shafts. Offers flexibility in shape but requires heavy machinery and experienced operators. Particularly common in Europe and Japan.

• Closed-Die Forging (Impression Die ) Best for smaller, high-precision parts like gear blanks or flange rings. Asia-based suppliers lead here, especially in South Korea and China.

• Seamless Rolled Ring Forging Growing fastest due to rising flange demand and lightweight tower design trends.

By Material

• Carbon Steel Still the most widely used due to cost-effectiveness and adequate strength for many onshore applications.

• Alloy Steel Preferred in offshore turbines or high-altitude sites where fatigue life and corrosion resistance are critical.

• Others (Stainless, Titanium Alloys ) Used in niche components or pilot turbine designs, especially in floating offshore wind.

By Region

• Asia Pacific Largest and fastest-growing market. China leads in both turbine installation and forged component exports. India is emerging as a hub for forging exports to Europe and MENA.

• Europe Strong domestic forging base in Germany, Italy, and Spain. Offshore wind growth around the North Sea is driving demand for larger, localized forging capabilities.

• North America Seeing a wave of forging capacity expansions as part of onshoring efforts tied to IRA subsidies. U.S. OEMs are shifting toward domestic forging partners.

• Latin America & Middle East & Africa (LAMEA ) Early-stage markets but gaining traction — particularly in Brazil, South Africa, and Gulf nations. Imports dominate for now, but local forging initiatives are being explored.

Scope Note : While this segmentation appears technical, it reflects an industrial transition. OEMs are no longer just buying metal shapes — they’re sourcing performance-critical components . That’s pushing forging suppliers to integrate metallurgy consulting, digital simulation, and just-in-time delivery models into their contracts.

 

3. Market Trends and Innovation Landscape

Wind turbine forging might sound like old-school metallurgy — but the reality in 2025 is anything but. Innovation is accelerating across materials, process automation, and supply chain strategy, all while OEMs demand tighter tolerances and faster lead times.

Here’s what’s shaping the next generation of forged components:

Larger Turbines = Larger Forgings

Turbines above 10MW capacity now dominate offshore installations, with rotor diameters pushing past 160 meters . That scale-up directly translates into bigger, heavier, and more complex forged parts — especially main shafts and rotor hubs . Traditional forging presses and heat treatment furnaces weren’t designed for this — so vendors are racing to upgrade.

One German forger recently installed a 10,000-ton press just to handle offshore shaft orders from North Sea projects. That’s a serious bet on turbine scale.

Demand for Near-Net Shape Forging

Waste and machining time are now competitive threats. That’s why OEMs increasingly ask for “near-net shape” forgings — components that come off the press almost ready to install. This trend favors closed-die and ring rolling processes combined with advanced simulation.

Digital tools like forging simulation software are now used pre-production to reduce flash, improve metal flow, and minimize rework.

Alloy Science Is Quietly Evolving

Forging is no longer just about brute strength — it's about fatigue life, hydrogen resistance, and corrosion protection. That’s pushing interest in low-carbon alloy steels , micro-alloyed grades , and custom quenching strategies.

Japanese and Korean forgers are leading here — quietly offering steel grades optimized for subsea exposure and 30+ year lifecycles.

AI + Automation in Forging Plants

The labor-intensive nature of forging used to be a bottleneck. Not anymore. Modern forging shops are using robotic billet handling , sensor-based heating controls , and AI-powered defect detection on the fly. This isn’t just about saving cost — it's about ensuring consistency at scale.

Chinese players, in particular, have scaled up massively by integrating fully automated ring rolling lines . Europe’s response? Smarter, not cheaper — with AI-integrated forging cells that reduce error rates in batch production.

Localized Forging Supply Chains

Supply chain security is now a strategic concern. The COVID-19 years exposed how dependent turbine OEMs were on overseas forgings. So now, local content laws and tariff policies are encouraging the rise of domestic forgers — especially in the U.S., India, and Brazil.

This creates opportunity for second-tier forging players to climb the value chain — especially if they can meet OEM quality audits and scalability tests.

Hybrid Forging-Casting Approaches

Some component designs are becoming too large or too irregular for traditional forging alone. The workaround? Hybrid forged-cast assemblies , where forgings are used in stress-bearing areas while castings fill the volume.

It’s an emerging trend, especially for rotor hubs and flange assemblies in floating wind platforms. Expect more modular assembly models by 2026.

Bottom line? Wind turbine forging is no longer just about making big steel parts. It’s about integrating metallurgy, mechanics, and digital precision to match the next era of clean energy engineering.

 

4. Competitive Intelligence and Benchmarking

This isn’t a commoditized steel business anymore. The companies thriving in wind turbine forging today are those that have evolved — offering not just tonnage, but precision engineering, digital assurance, and OEM-tailored partnerships . Here's how the competitive landscape is shaping up:

Bharat Forge (India ) Arguably the most globalized forging company from Asia. Bharat Forge supplies main shafts, gear blanks, and large rings for both onshore and offshore turbines. What gives them an edge is their fully integrated model — from in-house steel processing to precision machining and testing. They’ve invested heavily in automation and serve OEMs across Europe, North America, and Asia.

Also notable: their growing presence in U.S. operations, aligning with IRA-linked local content mandates.

Frisa (Mexico ) Frisa is a leader in seamless rolled rings and forged flanges , serving wind OEMs in the Americas and Europe. Known for metallurgical expertise and on-time delivery, they’ve carved out a niche with their ability to deliver custom forged geometries in short lead cycles. Their location in Mexico makes them a critical player for U.S. wind farm developers avoiding Asian supply chain delays.

Jiangsu Pacific Precision Forging (China ) A top-tier supplier in Asia, this company has scaled quickly by aligning with domestic turbine OEMs like Goldwind and Envision. They focus on closed-die and near-net shape forging , and increasingly supply components for floating wind platforms and hybrid hub assemblies.

They’re also leveraging government subsidies and cheap energy access to aggressively price in export contracts — something Western players struggle to match.

Thyssenkrupp Forged Technologies (Germany ) A legacy forging powerhouse with deep expertise in open-die shaft forging , especially for offshore and multi-megawatt turbines. They’re known for their robust quality assurance systems and partnerships with European OEMs like Siemens Gamesa . Thyssenkrupp has also invested in low-carbon steel integration and is experimenting with hydrogen-ready forgings for green steel sourcing.

Scot Forge (USA ) A U.S.-based open-die forger that plays a strategic role in domestic wind farm buildouts. Their custom job-shop model gives them flexibility to work on low-volume, high-spec projects — especially in retrofit or offshore pilot programs. They’ve won attention for meeting Buy America provisions with short-lead-time turbine shaft solutions .

Other Notable Players

• Farinia Group (France) – Known for high-strength gear blanks and forged coupling rings in European turbine fleets.

• NTN Steel (Japan) – Focused on ultra-precise forged parts for offshore turbines, leveraging Japan’s marine forging expertise.

• Lucchini RS (Italy) – Diversifying into offshore wind forgings from a legacy in rail and energy sectors.

Competitive Themes at a Glance

• Automation and vertical integration are key differentiators.

• Proximity to OEM assembly hubs — especially in India, Mexico, and the U.S. — increasingly determines contract wins.

• Material innovation (fatigue-resistant alloys, hybrid forging-casting) is becoming a gatekeeper for offshore contracts.

• Digital certifications, simulation-based QA , and just-in-time delivery are now standard expectations.

To be honest, this isn’t a race to the bottom on price anymore. Wind turbine OEMs want reliability, traceability, and structural guarantees — and they’re willing to pay for it when downtime costs millions.

 

5. Regional Landscape and Adoption Outlook

Wind turbine forging demand isn’t spread evenly. Some regions are building new forging ecosystems from scratch, while others are doubling down on long-standing expertise. What’s driving the shift? A mix of local energy goals, offshore wind projects, and geopolitical pressure to secure critical components closer to home.

Let’s walk through how this is playing out:

Asia Pacific – Dominant and Expanding

Asia Pacific leads both in wind installations and forged component output. China remains the largest consumer and exporter, with major players like Sany , Goldwind , and Mingyang procuring forgings domestically. Government incentives encourage full local content, keeping the majority of turbine shaft and rotor hub production in-house.

India , on the other hand, is rising as a global forging export hub . Bharat Forge and other tier-1 suppliers are shipping shafts and rings to Europe, the U.S., and MENA. India’s manufacturing cost advantage — combined with metallurgy depth — positions it as the long-term alternative to Chinese supply dominance.

South Korea and Japan focus more on high-spec offshore components , especially for floating wind. These markets have small turbine install volumes but export highly engineered parts — often with tight fatigue tolerances and marine-grade metallurgy.

Europe – Innovation Hub with Regional Hurdles

Europe’s wind turbine market is evolving fast — especially in North Sea offshore and Scandinavian floating wind . Countries like Germany , Denmark , and Spain still house top OEMs and mature forging companies ( Thyssenkrupp , Euskal Forging, FOMAS Group).

But energy security concerns post-Ukraine conflict are causing EU policymakers to rethink Asian forging reliance . The push is toward regionalizing key parts — even if it means subsidizing local forgers or scaling joint ventures with Indian or Mexican partners.

However, capacity constraints remain. Most European forgers aren’t built for today’s 100-ton+ offshore shafts — requiring either import reliance or large-scale equipment upgrades.

North America – Reshoring in Motion

The U.S. forging scene is in a transition. Historically reliant on imports from Asia and Mexico, American wind projects — especially in Texas, Midwest, and New England — are now under pressure to localize supply due to Inflation Reduction Act (IRA) mandates and offshore wind targets.

Companies like Scot Forge and Ellwood Group are expanding capacity, but the gap between domestic demand and forging output is still wide. The East Coast’s offshore wind buildup — led by projects like Vineyard Wind and Empire Wind — is creating urgent demand for localized forging of main shafts and nacelle flanges .

Meanwhile, Mexico is filling a strategic gap. Firms like Frisa now serve as a nearshore extension of U.S. forging needs, especially for rolled rings and closed-die components.

Latin America and Middle East & Africa (LAMEA) – Emerging but Uneven

Brazil leads in turbine installs in Latin America and has a modest domestic forging industry. However, most complex parts — especially main shafts — are still imported. There’s potential for local forging cluster development , especially near port cities like Salvador and Rio Grande.

South Africa and Morocco are exploring small-scale forging lines to support wind ambitions under national decarbonization plans. Still, infrastructure and metallurgical expertise are key gaps , often filled by imports from Asia or Europe.

Middle East countries like Saudi Arabia and UAE are investing in green hydrogen and utility-scale wind — but most forged parts are being brought in through joint ventures or global EPC contractors.

Regional Takeaway

• Asia Pacific is the scale engine — high volume, full supply chain, lower cost.

• Europe is the innovation lab — specialty alloys, simulation, and R&D partnerships.

• North America is the reshoring battleground — with policy, not price, driving the shift.

• LAMEA is the white space — long-term growth depends on infrastructure and training.

Bottom line: proximity, policy, and production agility are now just as critical as press capacity or cost per ton.

 

6. End-User Dynamics and Use Case

In the wind turbine forging ecosystem, end users aren’t just turbine OEMs. They include tier-1 suppliers, engineering contractors, and even government-backed clean energy developers. Each group has different priorities — from tolerances and lead times to traceability and supply security.

Here’s how the dynamics break down:

Turbine OEMs (e.g., Vestas , Siemens Gamesa , GE Vernova , Goldwind ) These are the primary consumers of forged parts. They source:

• Main shafts, rotor hubs, flange rings — usually custom-spec’d per turbine model

• Gear blanks and bearings — typically through gear system suppliers who pass demand upstream

Their key requirements?

• Quality assurance : Fatigue-tested, ultrasonic-inspected, and fully traceable forgings

• Just-in-time delivery : To align with nacelle or tower assembly schedules

• Global footprint : Ability to supply forgings to offshore sites in Europe, Asia, and the Americas

Insight: Many OEMs now bundle forging into EPC contracts or long-term supply agreements, reducing vendor turnover and improving material compatibility across turbine platforms.

Tier-1 Drivetrain and Tower Suppliers (e.g., ZF Wind, Broadwind , LM Wind Power ) These companies purchase forged parts like gear blanks , torque shafts , and flanges , and then integrate them into drivetrain assemblies or tower sections.

Unlike OEMs, they’re more price-sensitive — especially in onshore projects where margins are thin. However, technical specs still matter, especially as turbines scale up. Some have started co-investing with forging partners to lock in capacity or secure specific grades of alloy steel.

EPC Contractors and Wind Developers (e.g., Ørsted , Iberdrola , NextEra Energy ) These stakeholders don’t buy forgings directly, but they influence procurement through local content mandates and supplier audits.

In offshore projects, developers may even dictate forging origin — preferring “domestic steel” policies to align with subsidies or investor expectations. That’s triggered a recent trend: developers asking to review forging test certificates and QA reports before giving turbine supplier approvals.

National and State-Owned Energy Companies In markets like China, India, and the Middle East, SOEs play a double role — as both developers and policy shapers. They often prioritize domestic forging sources or require technology transfer from foreign suppliers.

This makes forging not just a procurement choice, but a geopolitical one.

Use Case: Wind Project in the U.S. Midwest

In 2024, a large onshore wind farm in Iowa faced delays due to shaft shipments stuck at a Chinese port. The developer, under pressure to meet IRA timelines, worked with GE Vernova to respec the turbine design around U.S.-made shafts from Scot Forge .

This meant shifting to a slightly shorter but thicker shaft geometry , which required minor gearbox adjustments. The result? Installation resumed within six weeks. The forgings cost more, but avoiding downtime saved over $3 million in project overruns.

Lesson learned? Forging flexibility and domestic availability now matter as much as metallurgy.

In this market, end-user expectations are shifting from price-first to resilience-first . Whoever can deliver certified, fit-for-purpose forgings on schedule — and closer to the turbine assembly line — will win the next round of contracts.

 

7. Recent Developments + Opportunities & Restraints

The wind turbine forging space is seeing a wave of changes — driven by technology shifts, offshore wind scale-ups, and trade realignments. The last two years, in particular, have redefined what's possible (and what's expected) from forging suppliers.

Recent Developments (Last 2 Years)

• Bharat Forge announced a joint venture with Holtec to build a new 100,000-ton forging press in Maharashtra (2024) — targeting large offshore shaft production for global exports.

• Frisa expanded its Nuevo León facility in 2023 with a new seamless rolled ring mill designed specifically for turbine tower flange production, aiming to reduce lead times to the U.S. and Brazil.

• Thyssenkrupp Forged Technologies launched a hydrogen-ready forging initiative in late 2023, experimenting with green steel integration for carbon-neutral shaft production.

• China’s Jiangsu Pacific Precision Forging partnered with Goldwind to co-develop hybrid rotor hub designs that combine forging and casting — optimized for floating wind installations.

• Scot Forge received a $30 million DOE grant in 2024 to expand domestic forging capacity for critical energy infrastructure, including wind turbine shafts and heavy-duty rings.

Opportunities

1. Offshore Wind Expansion The shift toward floating wind platforms and 15MW+ turbines is a forging game changer. These setups demand larger, fatigue-resistant parts — especially shafts, hubs, and bearing housings. Suppliers that can handle oversized forgings and marine-grade alloys stand to benefit.

2. U.S. and India Reshoring Trends The combination of IRA incentives (U.S.) and PLI manufacturing schemes (India) is pushing both OEMs and developers to localize supply. Forging firms in these regions have an opening to build long-term strategic relationships — not just transactional ones.

3. Automation and AI-Driven QA Forgers who integrate real-time defect detection, digital twins, and near-net shape modeling are gaining preference among top-tier OEMs. Why? Because automation isn't just about cost — it reduces batch errors and ensures audit compliance.

Restraints

1. High Capex for Large-Scale Forging Equipment To handle shafts for 12MW+ turbines, forgers need presses and furnaces many don't yet have. Building or upgrading these lines requires tens of millions of dollars , making it hard for new players to enter without financial backing or JV support.

2. Skilled Labor Shortage and QA Expertise Modern forging needs more than heat and hammer — it demands metallurgists, simulation engineers, and digital QA analysts. Many regions (especially in LAMEA) lack this skilled workforce, making it tough to scale consistently.

Reality check : The demand is there. The bottleneck is execution — in infrastructure, in people, and in trust between OEMs and forging suppliers.

 

Report Coverage Table

Report Attribute	Details
Forecast Period	2024 – 2030
Market Size Value in 2024	USD 8.6 Billion
Revenue Forecast in 2030	USD 12.9 Billion
Overall Growth Rate	CAGR of 6.8% (2024 – 2030)
Base Year for Estimation	2024
Historical Data	2019 – 2023
Unit	USD Million, CAGR (2024 – 2030)
Segmentation	By Component Type, Forging Type, Material, Region
By Component Type	Main Shaft, Rotor Hub, Flanges, Bearings & Gears, Others
By Forging Type	Open-Die Forging, Closed-Die Forging, Seamless Rolled Ring Forging
By Material	Carbon Steel, Alloy Steel, Others
By Region	North America, Europe, Asia Pacific, Latin America, Middle East & Africa
Country Scope	U.S., Germany, China, India, Brazil, Saudi Arabia, etc.
Market Drivers	- Offshore turbine scale-ups - Forging localization - Digital QA and near-net shaping
Customization Option	Available upon request