When you're buying quality brass hardware, you’ll often see the term solid brass. But what exactly does it mean and why does it matter whether a product is made from cast brass, forged brass, or sheet brass?

At Restoration Online, we specialise in solid brass hardware and work with a wide range of trusted suppliers across Australia and overseas. We carefully select products made using the most appropriate method for the item—whether it’s a door handle, cabinet latch, or sash fastener. In this guide, we’ll explain the key differences between cast, forged, and sheet brass so you can better understand the products you're buying.

What Is Solid Brass?

Solid brass is an alloy made from copper and zinc. It's strong, corrosion-resistant, and valued for its warm, classic finish, making it a popular choice for architectural hardware. Solid brass products are made entirely from brass, not just brass-plated or painted to look like brass.

However, not all solid brass is manufactured the same way. The method used—casting, forging, or cutting from sheet brass—affects the look, weight, strength, and finish of the final product.

Cast Brass

Cast brass is made by pouring molten brass into a mould. Once cooled, the shape is solidified and ready for finishing. This method is ideal for creating more detailed or decorative shapes.

Why it's used: Cast brass is commonly used for ornate knobs, period-style drawer pulls, and reproduction backplates, particularly where curved or raised detailing is needed.

• Advantages:
  • Suits traditional styles and intricate designs
  • Offers authentic character for heritage homes
• Things to keep in mind:
  • The casting process can leave minor surface imperfections like pitting or pinholes
  • Not quite as strong as forged brass, though perfectly durable for most applications

Many of the reproduction hardware ranges we stock are cast using traditional sand casting methods to closely replicate original vintage pieces.

Forged Brass

Forged brass is created by pressing heated brass into shape under high pressure. This process produces a denser, stronger product with a smooth, uniform finish. It’s often used for hardware that needs to withstand regular use.

Why it's used: Forged brass is a great option for modern door handles, latches, and heavily used fittings.

• Advantages:
  • Durable and highly resistant to wear
  • Clean, smooth finish with fewer imperfections
  • Excellent for high-traffic areas
• Things to keep in mind:
  • Not suitable for producing fine or intricate detailing
  • Typically more expensive due to the manufacturing process

Forged brass is the go-to choice for our more contemporary hardware lines where performance and appearance are equally important.

Sheet Brass

Sheet brass is flat brass cut into shape, then formed or stamped as needed. It’s best suited to items with a flatter profile or simpler geometry.

Why it's used: Sheet brass is ideal for sash lifts, cupboard latches, and push plates. It’s also used for certain backplates, particularly where a flat surface is desired.

A note on historical accuracy: Some original hardware from the early 20th century—such as Art Deco and Bungalow-style backplates—was traditionally made from sheet brass. Because we specialise in reproduction hardware, many of the brands we stock continue to manufacture these pieces the same way today. This allows you to restore your home using products that closely match the originals in both look and feel.

• Advantages:
  • Lightweight and cost-effective
  • Ideal for flat or minimalist designs
  • Keeps certain traditional styles true to form
• Things to keep in mind:
  • Not suitable for curved or raised designs
  • Slightly thinner than cast or forged options

Sheet brass isn’t a compromise—it’s simply the right tool for the job in many classic and practical applications.

Which One Is Better?

There’s no single “best” method—it all depends on the design and function of the hardware.

• Cast brass is perfect for ornate, traditional pieces
• Forged brass is ideal for strength and high-use situations
• Sheet brass is suited to flat, practical, or historically accurate hardware

At Restoration Online, we source from reputable manufacturers who use the appropriate method for each product. Whether you're after a sleek modern lever or a faithfully reproduced vintage latch, you can be confident that you're purchasing a piece that’s built to last.

Why It Matters

Understanding how your brass hardware is made helps you choose products that suit your needs and the character of your home. Whether you’re restoring a Federation house, renovating a mid-century kitchen, or fitting out a new build with classic finishes, the construction method plays a role in both appearance and performance.

Need Help Choosing?

Our team has been helping Australians choose quality solid brass hardware for over 15 years. If you’re unsure which product or finish is right for your project, get in touch—we’re always happy to help.