Define the piston requirements: bore size, stroke, compression ratio, material, and operating temperature
Select the piston design: flat-top, dome, dish, or custom profile
Choose the material: cast aluminum, forged aluminum, steel, or other alloy
Create the CAD model with crown, skirt, ring lands, pin boss, and reliefs
Run strength and thermal analysis on the design
Prepare the mold, forging die, or billet stock based on the manufacturing method
Form the piston blank by casting, forging, or CNC machining
Heat-treat the blank if required by the material and process
Machine the crown, skirt, ring grooves, pin bore, and oil passages
Add surface treatments or coatings if needed
Deburr and finish all edges and critical surfaces
Measure all dimensions and verify tolerances
Balance the piston if required for engine assembly
Inspect for cracks, porosity, and defects
Package and store the finished piston for installation