What is Roll Forming?
Roll forming is a continuous bending operation in which a long strip of metal (typically coiled steel) is passed through consecutive sets of rolls, or stands, each performing only an incremental part of the bend, until the desired cross-section profile is obtained. Roll forming is ideal for producing parts with variable lengths or in large quantities.
Examples of roll formed products include:
- HVAC registers
- Fenders
- Door frames
- Auto trim
- Fence posts
- Steel shelving
- Garage door slats
Roll Forming Facts
- Some applications can be justified with as little as 3,000 pieces of a particular part per year, however, it generally takes about 75,000 pieces of a given part per year to justify a roll former.
- Roll forming typically produces a more consistent part than other forming methods.
- For roll formers that run from coiled material, product lengths are limited only by the amount of material in the coil. Furthermore, product lengths can be easily changed on-the-fly.
- Ferrous and non-ferrous metals such as cold or hot rolled carbon steel, stainless steel, aluminum, brass, and copper, can be roll formed.
- Pre-painted, galvanized, vinyl clad, and plastic enclosed metals can also be roll formed. By doing so, secondary coating operations can be eliminated.
- Engineered features; Locating holes, "knock-outs", and notches can all be punched in the parts in-line before the finished parts are cut to length.