The two processes used to manufacture a wheel are casting or forging, which are described here.

One-piece Cast Wheels
A cast wheel is made by pouring molten metal into a mold. Three types of casting methods exist: low pressure (most common), counter pressure, and high counter pressure molding. Each particular method yields different weight, strength, and finish characteristics. Either counter pressure method reduces impurities and yields a stronger wheel than with the low-pressure method. Casting is also used to manufacture a piece of a multi-piece wheel.

Multi-piece Wheels
Casting and forging methods can be combined to achieve a wheel of a particular strength and weight. Because multiple pieces are involved, different metals can be used, such as a steel barrel welded to a cast aluminum center. Similarly, an extruded aluminum barrel can be welded to a forged aluminum center. Different metals, such as magnesium and titanium or additional splits, such as three-pieces, create truly custom wheel applications.

Forged Wheels
A solid piece of aluminum (a billet) is heated and pressed by millions of pounds to “forge” it into the desired shape and machined to the desired finish. Wheels made from this process may erroneously be referred to as "billet wheels". The process for forged wheels uses less material than that for cast wheels, resulting in a lighter wheel for the same tensile strength. Roll forging runs the aluminum through rollers, and uses less material, making these wheels very light