Custom Roll Forming Division
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Custom Roll Forming Process

For complex shapes, two or more strips can be rollformed then welded together to form a composite section.Rollforming continuously forms coiled sheet or strip into shapes of uniform cross-section and thickness by bending across the material’s linear axis. Typically, through the forming action of roller dies, material is shaped progressively on a long horizontal line then cut to customer-specified length. Sometimes, previously cut stock is fed through the rollforming line, eliminating the need for end-of-line cutting. Punching, notching, slotting, embossing and other operations can be incorporated into the rollforming line. The process can produce hollow or semi-hollow shapes.

Competitive processes: Extrusion, hot rolling.

Parts produced: HVAC and construction industries are big consumers of rollformed products. These include ductwork as well as doors and wall panels. Rollformed products also find great use on roadways as sign posts and guardrails. Other products include shelving, airframe parts, window and door frames, raceways and troughs, telescoping bleacher seating, electronic enclosures, drawer slides and various types of rails.

Benefits: Should your needs fall to parts with uniform cross-sections, rollforming can make them in high volumes, cutting the parts to the length needed. In-line processes to punch, notch and perform other functions help reduce cost and lead time. Inline pre- and postpunching eliminates costly secondary operations in rollforming.Generally, rollformed parts offer a strength advantage over competing processes in structural-rigidity applications.

Capacities: Sizes of parts produced are limited only by shipping and handling concerns. The process typically runs at speeds from about 5 to more than 600 ft./min., depending upon part complexity and use of in-line non-rollforming operations. The type of material worked also affects process speed.

Materials: Any material that can be cold-formed from sheet is a candidate for rollforming.

Should I use it? The process will yield high volumes of parts, to any length desired. Use it for parts with similar cross-sections throughout. Also, the process is not limited to straight parts—it can sweep material into a continuous radius or a circular ring. Rollforming allows the formation of two different materials simultaneously to produce a clad shape in one operation. Note: Product design is limited to material of constant thickness, and the process does not provide the ability to strengthen bends with fillets.