Custom Metal Manufacturing for the Energy Industry
Since 1980, The Federal Group USA has partnered with companies across traditional and renewable power sectors to deliver reliable, precision-built components. As an American-owned company, we support critical energy infrastructure by producing high-quality metal parts that are trusted in demanding environments.
Request a QuoteWhy Choose The Federal Group for Custom Metal Manufacturing in the Energy Industry
Extensive Capabilities
Sand casting, investment casting, hot forging, and metal fabrication for energy industry applications.
Material Diversity
TFG works with a wide range of materials including aluminum, stainless steel, brass, exotic metals, titanium, and more.
Custom Finishing
We perform secondary operations such as CNC machining, zinc plating, powder coating, and black oxide finishing to meet energy equipment requirements.
Quality Assurance
Dedicated quality engineers, real-time performance monitoring, and comprehensive testing capabilities.
Our Metal Manufacturing Services for the Energy Industry
Since 1980, The Federal Group USA has partnered with companies across traditional and renewable power sectors to deliver reliable, precision-built components.
- Engineering: TFG partners with energy OEMs to provide DFM support—engineering design reviews, design optimization, and cost-reduction recommendations (materials and process selection)—to deliver reliable, field-ready metal components.
- Manufacturing: We cover everything including project management, material handling, tooling builds, production, and secondary operations.
- Quality: Our in-house quality team performs in-process inspections and can provide advanced metrology/CMM verification, along with FAI and PPAP submissions, to confirm critical dimensions, tight tolerances, and repeatable performance for energy-industry components.
- Logistics: TFG delivers production-ready energy components with modern supply chain management, real-time shipment visibility, warehouse support, and custom inventory programs aligned to your release schedule.
Common Materials Used in Medical Equipment Manufacturing
To meet the stringent requirements of energy equipment manufacturers, TFG selects each material for its unique combination of strength, weight, and corrosion resistance. Here are the materials we commonly use in energy component contract manufacturing.
Stainless Steel
Delivers strong corrosion resistance (including in wet, saline, or chemical environments) while maintaining strength and reliability across demanding temperatures and service conditions.
Aluminum
Lightweight, naturally corrosion-resistant, and offers a strong strength-to-weight ratio, making it ideal for things like enclosures, frames, heat-management parts, and offshore or outdoor equipment.
Titanium
Ideal for energy industry components because it offers an exceptional strength-to-weight ratio, outstanding corrosion resistance in harsh and marine environments, and reliable performance at elevated temperatures.
Carbon Steel
High-strength at a cost-effective price, with reliable machinability and weldability for everything from piping and structural parts to pressure-containing equipment.
Common Manufacturing Methods for the Energy Equipment Industry
With decades of experience, The Federal Group uses a wide range of advanced manufacturing processes to deliver custom components to the energy sector.
- CNC Machining – TFG uses CNC machining to produce precise components with ±0.01-inch tolerances. This is an ideal manufacturing method for parts with complex geometries in both small and large-scale energy projects.
- Hot Forging – This high-strength forming process produces tough, fatigue-resistant components for demanding energy applications, including flanges, drill bits, pipe fittings, shafts and spindles, couplings, hooks, and custom high-strength fasteners.
- Investment Casting – Ideal for producing near-net-shape, metal components for demanding energy industry applications, including pumps, impellers, manifolds, compressor components, and fittings.
- Sand Casting – This casting process allows us to produce custom components for energy systems, including turbines, housings, valve bodies, and structural parts.
- Sheet Metal Fabrication – TFG uses sheet metal fabrication to manufacture equipment enclosures, control panels, skid bases and frames, brackets and mounting plates, ducting and housings, shrouds and guards, and battery/inverter cabinets, among other components.
Secondary Operations
The Federal Group provides secondary operations for energy-industry metal components to improve corrosion resistance, wear performance, and service life in harsh environments.
Our finishing and post-processing capabilities include powder coating, e-coating, hot-dip galvanizing, zinc/nickel plating, electroless nickel, passivation (stainless), anodizing (aluminum), painting/epoxy coatings, heat treating (as required), plus mechanical services like deburring, polishing, and grit blasting.
Not Sure What You Need? Let’s Talk Engineering
The Federal Group USA partners with energy equipment manufacturers, procurement teams, and project managers to solve problems early in the design process. We don’t just make parts—we’re here to offer engineering support and design consultations that help guide your project through the next steps. From design to delivery, when precision and compliance matter, The Federal Group USA is here to talk engineering.
Start Your Custom Energy Component Manufacturing Project Today
With over 45 years of experience, The Federal Group USA offers contract manufacturing for the energy industry to provide clients with ISO-certified quality components. Request a quote or speak with an engineer to get started on your custom project today.
Client Testimonials
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Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor 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!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike 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.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve 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.Trustindex verifies that the original source of the review is Google.Sean Connelly2023-06-21The 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!Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The 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.Trustindex verifies that the original source of the review is Google.Marshall2020-06-30Excellent customer service and products!
