Roll forming is a continuous shaping operation in which sheet or coiled metal is plastically deformed along the linear axis. Rolls set in pairs (top and bottom) form the metal in a series of progressions until the desired cross-section is reached.

There are many economies available through roll forming. Less labor is involved than with multiple stamping or press operations. Many operations, such as piercing and punching, can be included in-line on a roll form set-up. Roll forms can be cut off at almost any length using the same set of tools – tools for each length of a part are not required as with a stamping die. Material utilization is very high – there is very little waste.

Like any other metal manufacturing process, roll forming has a sweet spot. Roll forming is great for projects with:

• High Volume – Roll forming is most cost-effective for orders of 10,000+ parts. This is especially true if the order and design are highly repeatable.
• Feature Attractions: Metal channel designs that require intricate bends, holes, notches, knockouts, labels, stamping, or embossing – or a combination of two or more of these happen in line with no additional operations necessary.

Virtually any bendable metal can be roll formed. Roller Die has experience forming:

• Aluminum – Common and heat treatable alloys
• Brass
• Bi-metals
• Coated Metals – clad, galvanized, pre-finished, pre-painted, and vinyl laminated
• Coated Alloys – for aerospace, petrochemical and military applications
• Copper and Copper alloys
• Steel – Carbon, alloy and stainless steel, HSLA, cold rolled, hot rolled, all commercial quality steel and aluminized or galvanized steel
• Tin alloys
• Titanium