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.

December 8, 2024

Anodizing aluminum parts can be an efficient way of adding enhanced mechanical properties to parts or improving their aesthetics. Read...

Everything You Need To Know About Cast Iron: Types, Properties, and Applications

December 2, 2024

Metals are integral raw materials in the manufacturing industry. One example, iron, is second in abundance to aluminum and makes up...

November 21, 2024

Metal casting is one of the most efficient and versatile manufacturing processes today – and with good reason. This technique,...

Celebrating Teamwork and Success at The Federal Group

November 13, 2024

Recently, our team at The Federal Group gathered for a celebratory lunch. As a custom metal parts manufacturing business with...

Understanding the Wire Forming Process, Techniques, and Applications

October 29, 2024

Wire forming is a cornerstone of modern manufacturing, shaping everything from everyday items to critical components in the construction, warehousing,...

A Guide to Understanding the Cold Heading Process

October 25, 2024

Cold heading is a high-speed metal forming process that shapes parts at room temperature without the need for heat. This...

A Comprehensive Guide to the Investment Casting Process

October 21, 2024

Investment casting, also known as lost wax casting, is a 5,000-year-old metalworking technique that blends ancient craftsmanship with modern precision....

October 13, 2024

This year marks the 44th anniversary of The Federal Group, a significant milestone in our journey as a leading force...

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 10 reviews 
    
 
 
   
 
 
        
   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.
  
 
       
   Dave Scillion 
 2020-06-24
 
 
 Trustindex verifies that the original source of the review is Google. Federal Group is a terrific supplier to work with.  Quality parts at competitive pricing.  Richard Jegla is great to work with there!