A system and method are provided for forming thermoplastic material using rotary forging. A volume of a thermoplastic material is delivered. The thermoplastic material is transported between a first rotating forging device and a second rotating forging device. The first forging device defines a first forging region in its surface, which receives the thermoplastic material. The thermoplastic material is at or above a forging temperature and flows into the first void region and shapes a core element from the thermoplastic material. The thermoplastic material is substantially solidified into the core element. Then, the core element is transferred from the first rotating forging device.