Cast vs Forged Irons: What’s The Difference?

We often get asked about cast vs forged irons and, in the most simple terms, casting and forging refers to the manufacturing process used to make each type of iron.

The majority of irons are made by casting, a building process that involves pouring molten metal into a mould to produce the head.

Because there is a mould involved,  manufacturers can be more creative, particularly with large cavity back heads that benefit from additional weight nearer the outside of the head to reduce twisting on off-centre hits.

In comparison, forged heads are made from a piece of soft steel, which is beaten into shape. The steel used in forging has to be much softer, and this often leads to players commenting on a better feel at impact.

As Mizuno’s Senior Club Engineer Chris Voshall explain’s in the video above, the molten metal pouring process can lead to air gaps in the steel. These gaps then  break up the vibrations at impact that lead to feel, whereas in forged heads, the continuous grain through the metal has no air gaps, so you’ll find better vibrations for more a consistent feel.

Another difference between cast vs forged irons is that the forging process is much more labour-intensive, and that is why they generally cost more to buy.

Contrary to what you might believe, the benefits of forging aren’t just for the likes of Luke Donald. Unlike 20 years ago when we associated compact blades with feel, nowadays the modern forging process means designers and craftsman can take larger headed irons like the Mizuno JPX EZ Forged and deliver softer feel and feedback for mid and higher handicappers to enjoy.