What is Roll Forming?
Roll Forming is a process in which a strip of metal, usually in coil form, is continuously passed through a series of roller dies and progressively formed to the desired shape.
In many cases roll forming eliminates multiple stage production, sub-assembly and finishing operations. Any number of subassembly operation can be continuously combined in the roll forming operation.
What are the benefits of Roll Forming?
Roll forming permits consistent adherence to close tolerances, producing shapes and dimensions to fit your application. By eliminating the need for secondary operations such as notching and deburring, production speed is increased and assembly costs are reduced. roll formed material generally has a structural strength advantage over other processes. Hollow or semi-hollow shapes can be produced with thinner walls than competing processes.
Is Roll Forming cost effective?
YES. Roll Forming is the most economical choice for many companies that look to streamline their production and reduce overall cost. The high-speed continuous nature of roll forming is especially beneficial for large volumes.An experienced Custom Roll Former will incorporate a number of secondary operations in one line. Savings are realized through the need for fewer component parts, fewer post-production operations and reduced manufacturing cost.
What materials can be Roll Formed?
Roll Forming is suitable for almost all metals. Some of the most common are:
Many other materials. Unlike other processes roll forming is also ideal for various metals that have been painted or coated.
A custom roll former will be able to provide more information about what materials will work best for your application.
Can all shapes be Roll Formed?
Many shapes are easily roll formed. Although not all shapes may appear to be suitable for roll forming, it is worth considering this process in your evaluation. In many cases an experienced roll former can provide alternate designs to fit your needs.
What is involved in designing and manufacturing a new part?
Custom Roll Forming is a creative process. An experienced roll former can guide you through the early planning stages providing the benefit of years of experience in design and engineering. Several stages of redesign may occur in order to trim costs and simplify production and assembly.
Can Roll Formed parts save labor and inventory cost?
YES. A custom roll former can deliver finished shapes, cut to exact length for assembly in your production. This frees up valuable manufacturing space in your plant and completely eliminates scrap loss. By eliminating secondary operations, labor costs are also greatly reduced.
What industries benefit from custom Roll Formed parts?
All industries can benefit from the flexibility of roll forming. Many companies that use roll formers do so because they require consistent adherence to close tolerances.
Will Roll Forming work for my application?
Roll formed shapes can be economically produced from an almost limitless variety of stock coated or uncoated eliminating the need for secondary finishing operations. Uniformity assures precise fit and simplifies production, speeds assembly and minimizes rejects. Roll forming can greatly benefit any operation.If you would like help in evaluating whether roll forming would benefit your company please contact us.