We make metalwork.

We help clients produce premium metal parts by providing industry-specific expertise, cost-effective solutions, a powerful global manufacturing network, and peace of mind with every project.

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Our Process

Explore our end-to-end manufacturing process.

Enhancing and improving designs for 40+ years.

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Castings, Forging, Metal Fabrication, and more.

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Ensuring every product is built-to-print.

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Improving the supply chain experience from start to end.

Cold heading has typically been used to create pieces like simple fasteners, though with technology always improving, cold heading can be used to create highly specialized fasteners and specialty pieces.

Cold Heading See All Capabilities

As important as it is to create quality metal parts, they won’t do any good unless you have something that holds them all together. Such is the job of fasteners.

Custom Fasteners See All Capabilities

Industries all over the country use metal stamping to create intricate components for machinery.

Metal Stamping See All Capabilities

We provide full-service metal fabrication services, working with you from product research to manufacturing.

Metal Fabrication See All Capabilities

Metal forging is the process of shaping a piece of metal using continuous pressure. Specialties include cold forging, hot forging, and more.

Metal Forging See All Capabilities

Aluminum die casting represents a safe, reliable process by which metal pieces can be cast and molded for a variety of purposes.

Aluminum Die Casting See All Capabilities

Precision CNC machining works with a variety of materials including metals, woods, acrylics, foams, and thermoplastics.

Precision CNC Machining See All Capabilities

Screw machining is the process of rapidly spinning lathes that shave metal down to the desired size.

Screw Machining See All Capabilities

Our Products

From Prototype to Production

Our team of engineering and manufacturing experts have experience creating products for a wide variety of industries.

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A few of our clients who have benefitted from our engineering and manufacturing expertise.

Quality Management and Integrity

At The Federal Group USA our staff is on the ground for each phase of the Supply Chain Management operation. The Federal Group USA employs engineers who direct machining processes and inspect tooling and equipment to ensure that we are meeting all demands and requirements.

Our ISO 9001 quality management system is under continuous improvement to satisfy our customers’ ever changing requirements. The Federal Group’s Quality Management System is certified ISO 9001 by NSF International. Incorporating world-class excellence, in an ongoing effort to ensure your success.

Mastering Brass CNC Machining: Techniques, Tips, and Innovations

April 24, 2025

From plumbing fixtures to electrical components and bearings, brass is a staple of our everyday lives. This copper-zinc alloy is...

Aluminum vs Steel: The Best Metal for Your Project

April 8, 2025

Steel and aluminum are the two most widely used materials in metal manufacturing. Despite their obvious visual similarities, several key...

March 26, 2025

Since its inception in the late 1940s, computer numerical control (CNC) machining has transformed manufacturing. The process involves programming a...

CNC Machining for the Medical Industry: How It Works

March 6, 2025

CNC machining is a computer-assisted manufacturing process that has redefined product creation used across various industries. The revolutionary technology allows...

Die Casting vs Sand Casting: Which Is Best for You?

February 24, 2025

Understanding Metal Forging Processes, Methods, and Applications

February 14, 2025

Metal forging is the process in which metals are formed and shaped using compressive forces. The forces are delivered using...

What Is Carbon Steel? A Comprehensive Guide

February 6, 2025

Steel is an alloy metal that mainly comprises carbon, iron, and other trace elements in varying concentrations. The difference in...

CNC Router vs Milling Machine: Which One Is Right?

January 29, 2025

Computer numerical control (CNC) machines allow manufacturers to create custom parts that serve unique purposes. They operate with the help...

Case Studies

Handlebar Assembly Tolerance Study

The following report is an analysis of the hole position tolerance for a handlebar weldment. We have further studied our manufacturing and inspection practices, and have determined that 100% of our parts meet the drawing requirements. We understand that there is an issue fitting the handlebars to the mating “pod” assembly, so you will find our suggestion near the end of this report.

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     Excellent  
     Based on 11 reviews 
    
 
 
   
 
 
        
   Sean Brockhouse 
 2025-04-20
 
 
 Trustindex verifies that the original source of the review is Google. Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines.  Outstanding customer service!!
  
 
       
   Melissa Quiroz 
 2024-08-09
 
 
 Trustindex verifies that the original source of the review is Google. Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!
  
 
       
   Alex Armstrong 
 2023-12-15
 
 
 Trustindex verifies that the original source of the review is Google. Steve was great to work with and was always available when needed.
  
 
       
   Jon Ramsey 
 2023-10-07
 
 
 Trustindex verifies that the original source of the review is Google. Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success.

Would recommend and I plan to use them for future projects.

Thanks again Mike and TFG team.
  
 
       
   Nic Robinson 
 2023-10-05
 
 
 Trustindex verifies that the original source of the review is Google. 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 and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.
  
 
       
   Sean Connelly 
 2023-06-21
 
 
 Trustindex verifies that the original source of the review is Google. The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!
  
 
       
   Sher Stahl 
 2020-07-10
 
 
 Trustindex verifies that the original source of the review is Google. The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.
  
 
       
   Marshall 
 2020-06-30
 
 
 Trustindex verifies that the original source of the review is Google. Excellent customer service and products!
  
 
       
   Mae Winter 
 2020-06-25
 
 
 Trustindex verifies that the original source of the review is Google. Great parts, great prices and great people! Everything you want and need in a trusted supplier.