Cobalt chrome forging of femoral knee implants and other components

A method of creating a cobalt chronic femoral knee component includes the steps of: providing a forging press including first and second bust forging die parts spaced apart from each other and movable toward each other, the first and second bust forging die parts including respective femoral knee component shaped cavities; placing a cobalt chrome ingot heated to a temperature of between about 2050° F. and about 2300° F. between the first and second bust forging die parts in alignment with the femoral knee component shaped cavities; and bringing the first and second bust forging dies parts together in a bust blow against the cobalt chronic ingot under a pressure between about 1500 tons and 2000 tons creating a femoral knee bust forging. Additional steps may include cooling the femoral knee bust forging, heating the cooled femoral knee bust forging, providing a forging press with first and second block forging die parts, placing the heated femoral knee bust forging between the first and second block forging die parts, and bringing the first and second block forging die parts together in a block blow against the heated femoral knee bust component creating a femoral knee block forging.