Roll forming is a continuous shaping operation, ideal for making components with a consistent profile running the entire length of the part, in which coiled sheet metal is passed through a horizontal series of rotating dies to produce a uniform cross-section shape. Each set of rolling dies makes an incremental change to the sheet metal until the desired profile is achieved. The resulting piece is then cut to the specified length of the final part.
The benefits of using a roll forming process versus a press brake or other bending operation can be seen in cost reduction, quality and consistency of parts.
Cost reduction comes into play simply due to the speed and continuity of the operation which allows for higher volumes at lower costs. Actions such as notching, perforating and punching can be incorporated into the dies reducing or eliminating the need for secondary operations.
In typical bending operations you are limited by the length of your press brake, whereas in roll forming the length of a part is almost limitless.
We can also assist with an array of additional operations such as welding, stamping and assembly, and can even provide inventory management and logistics services.