The present invention discloses a Fluid End and its manufacturing method. The conventional fluid end manufacturing methods involve machining of all surfaces. This demands more input stock for manufacturing process and a lot of material wastage during machining process. In the conventional processes involving open die forging followed by machining result into only about 34% utilization of material. In the present invention, fluid end component geometry is optimized. Assembly surfaces are machined whereas other or non-assembly surfaces are as-forged condition. The method of invention also results in significant reduction in machining time and chip removal. The present invention also discloses a process of manufacturing using a combination of open die and closed die forging, and machining. It involves the steps of cogging an ingot to form billet for closed die forging using open die forging, forging the billet in closed die using forging equipment, semi-finish/rough/partial machining, heat treatment, drilling and finish machining the component. Most of the non-assembly areas of the fluid end are left in as-forged condition.