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Roll forming is a versatile and cost-efficient process for shaping metal into customized cross-section profiles. Usually called “cold roll forming,” because the metal is formed in its hardened state, roll forming is used throughout a wide range of industries to produce parts and components for everything from metal forming in automobiles to appliances to airplanes and houses.

For products that may be roll shaped, the process gives a host of benefits and advantages over alternative approaches.

EFFICIENCY

Most roll forming is done with lengthy strips of metal in coils, so the process is high-speed, with low labor calls for, allowing higher volume production for many products with higher efficiency than with press braking or stamping. Additional processes, similar to punching or notching, will be incorporated into a roll-forming production line, additional reducing labor demands, and outputting completed products ready for distribution. Press braking requires separate processes for punching, notching, or perforating, adding time, labor, and expense.

SAVINGS

Roll forming is a no-heat system — reducing energy prices — that gradually bends the metal, in phases, into its closing form by passing it through a series of custom-designed rollers. Roll forming doesn’t create the software wear that stamping does, the process eliminates the need for machining, akin to deburring, often required with press braking. Identical parts minimize from long strips mean no wasted scrap, and roll-formed parts can be of almost any size, while press braking limits length to the scale of the machine. Roll-shaped metal parts produced in quantity are virtually always more cost-effective than plastic or extruded versions.

FLEXIBILITY

Even advanced cross-section profiles which are a challenge or are not possible with stamping might be easily created with roll forming, together with round, closed, and C-shaped profiles. Almost any metal, ferrous or nonferrous, may be roll-formed, while extrusion is limited to only aluminum or brass. Roll forming also permits the shaping of metals already completed with paint, plating, or coating, while extrusion works only with unfinished, unplated stock, and press braking of completed metals requires additional handling and processes, costing time and money.

PRECISION, QUALITY AND CONSISTENCY

Roll forming can be designed to meet very tight tolerances. Products are more uniform and constant across runs than with press braking, facilitating ease of use in applications such as assembly line manufacturing, where elements must fit right every time. Roll forming can produce a lot higher quality products and parts than extrusion.

ADVANCED DESIGN TOOLS

Mills offers inline sweeping and arcing capabilities that can create complicated, swish curves and bends for aesthetics in products corresponding to automotive or appliance trim.

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