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Roll Forming

IQS Directory is a top industrial directory listing of leading industrial roll forming companies and suppliers. Access our comprehensive index to review and source roll forming companies with preview ads and detailed product descriptions. These roll forming companies can design, engineer and provide roll forming services to your specifications and application need. A quick and easy to use request for quote form is provided for you to contact these roll forming companies and suppliers. Each company has detailed profile information, locations, phone number, website links, product videos and product information defined. Read customer reviews and product specific news articles. We are the right resource for your information requirement whether its for a manufacturer of roll formed parts, steel roll formed, metal roll forming.

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Our roll forming is among the best in the world. Located in Chicago, Illinois we are able to provide products to the world. We have technicians that are able to work with you in order to come up with the product that you have been searching for. Our research and development department ensures that we are on the leading edge of innovation at all times. Trust us with your business and contact our representatives today for more information!
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Johnson Bros. is a leading manufacturer when it comes to roll forming metals, pre-finished and plain. Such as profiles, U-Channels, C-Channels, J-Channels, Hat Channels, Box Channels, Zee Channels, Strut Channels, moldings, angles, rings (bent inline), frames, lock seam & open seam tubing. For runs large or small, our fully capable process goes from concept to completion.
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With over 50 years of experience, United Roll Forming specializes in roll forming for a variety of industries. Our products are the result of state-of-the-art machines that provide both quality and efficiency. We are extremely proud of our ability to take any type of metal and transform it when other suppliers gave up. No matter the size or shape, turn to us for your fabrication needs.
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Producing five different standard products, as well as complicated roll forming sections and secondary operations such as notching, punching and fabricating, is Roller Die & Forming Company, Inc. They provide in-house tool room for quality metal moldings and the employees have been trained in every aspect of the roll forming process, representing over 200 years of experience.
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ISO 9001:2008 certified manufacturer specializing in custom roll forming. Unique profiles are run in gauges from 0.005" to 0.165" and widths up to 48" on 35 lines. Adding in-line operations may enhance your product. Design assistance is available to seek an economically creative solution. Economical production lots often begin around 5,000 lineal feet. For more information on us or our products, give us a call today!
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Since 1958 Cardinal Manufacturing Company has maintained its commitment to provide excellent service and quality while remaining competitively priced. We specialize in producing roll forming parts to your specific material, shape and size specifications. We even design and manufacture our own tooling and equipment. Let Cardinal Manufacturing take care of your next project.
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We are able to provide you with products that won't quit and offer any kind of roll forming that you may need. Our name alone means high quality angles, channels, special shapes, whatever you need, whenever you need it. We are dedicated to providing you with service that stands above the rest. Let us amaze you today! Contact our friendly customer service employees via our website using our easy form or by email today!
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At California Steel & Tube, we can help bring your steel tube or roll formed product concept to life. We are capable of creating a wide range of shapes through roll forming sheet or strip. We have a large inventory of stainless steel, aluminum, and more. Give one of our representatives a call if you would like more information about our products and services.
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When it comes to roll forming nobody does it like we do! We are committed to bringing new innovations with every job we do. It is our policy to ensure that our customers receive 100% customer satisfaction in order to keep them coming back to us for all of their roll forming needs. Our staff will be able to match you with a product that will surely fit your requirements. Get in touch with our customer service representatives today to learn more!
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Industry Information

The Cost Benefits of Roll Forming

Roll forming companies have known for many years the many benefits of using the process of roll forming to create complicated and complex metal shapes. Roll forming is often used to manufacture large metal pieces, and it has many benefits over other forms of metal shaping such as pressbreaking. If you are interested in using roll formed metals, consider some of the following advantages:

Lower costs: Roll forming requires less material handling and labor. This creates a continuous production and lowers the cost-per-piece of each metal piece.

Increased consistency: For large orders, roll forming creates pieces that are identical every time. You will find more accuracy, uniformity, and consistency in individual pieces as well as the entire production lot.

Fewer secondary operations: With roll forming, you can add additional extras, often saved for secondary processing, at the same time. During roll forming you can cut, notch, perforate, punch, and otherwise change the metal during the initial production. This also increases the structural integrity of the piece and better parts joining.

Rapid delivery and turnaround times: Because roll forming is done mostly with one simple process, parts can get to your sooner. Basically, roll forming is a one-stop shop that allows your metal parts to get to you sooner with greater accuracy and cost savings.

For these reasons and more, if a company has the option of choosing to use roll formed metal, you will not be sorry. Roll formed metal is highly effective and beneficial in a multitude of ways.

Roll Forming

Roll forming is a metal forming process in which metal is shaped by a series of rollers. Roll formers can create shapes out of aluminum, steel, brass, zinc, zirconium and most other metals. Roll forming produces some of the most widely used metal products in existence.

Examples of Roll Forming products include angle irons, aluminum angles and steel angles which are used in carpentry and building applications. Metal trim and metal channels are also widely used in construction, but they are also used in the manufacture of industrial, commercial and consumer products. Metal rings are used to embellish buttons on telephones, in elevators and even clothing. They also prevent hoses from disconnecting, street signs from falling and they secure lock hardware in doors. Metal wall panels can improve the appearance of a wall in an office, or it can protect a wall in a factory from flying debris or sparks. All of these roll formed products are produced in stock quantities by metal fabricators because of the constant, high demand for them. However, in the many cases in which a stock roll formed product is not appropriate, custom roll forming provides specialized products in large quantities and of uniform quality. Roll forming is a modular process; roll formers can be configured to produce all manner of metal shapes.

Roll formed parts boast a variety of advantages over alternative forming processes; roll formers generate very little scrap material while simultaneously improving the qualities of strength and durability in the metals they process; this makes them very cost-effective compared to other metal shaping processes. Roll forming is a cold forming process, which means that no heat is used to make the metals pliable. Instead, compression and force are used to shape the metals; the compressive stress created by the rollers imparts qualities of strength as they shape the metal. Other metal shaping processes like thermoforming can create larger amounts of scrap, they can be more energy intensive and the machinery can be expensive. Also, roll forming is a continuous process, which means that as long as a roll former is fed with a continuing supply of metal, it can continue producing shaped products. The only major drawback to roll forming as a metal shaping method is the labor intensity of roller configuration; this process requires a trained professional to precisely set roller systems to ensure a flawless finished product. Recent advances in computer control systems have made this process easier, but it can still be costly.

Roll formers work by forcing metal through a series of rollers. At the beginning of a roll forming process, a stock of metal (which is usually coiled to allow for easy access by the machine) is fed into the first set of rollers. The first sets of rollers in every roll former are designed in advance to fit tightly around the contours of the metal stock. Each subsequent set of rollers is slightly different in terms of position, allowing for the gradual shaping of the metal as it passes through the rollers. For example, if a customer orders circular metal clamps, a roll forming company takes a stock of metal strip that looks like this: ---. That strip is fed into a roller system that creates circular metal clamps. The first set of rollers may look like this :::: with the metal strip gripped horizontally in the middle. Slowly, the position of each successive roller in the system would change so that the metal strip, whose horizontal cross section originally looked like a straight line, changes until it looks like this: ?. One drawback of roll forming is that it cannot create sealed ring products; a roll formed metal ring must always be welded or connected with fasteners in order to become sealed.

Roll forming services can quickly and efficiently accommodate high-volume orders. Because roll forming is continuous, high-volume roll form production is often very cost-effective. However, roll former configurations vary in terms of output speed; a given roll former can produce anywhere between 30 and 600 feet of roll formed metal products per minute. Most roll formers are capable of using near 94% of stock metal material during forming operations, which minimizes waste, maximizes efficiency and boosts profitability. Roll forming operations that involve punching or other surface area reduction services produce more waste than those that don't provide such services. Roll forming is an excellent choice for the shaping of coated, finished, cured or otherwise treated metals. Because roll forming processes don't involve heat, and because rollers can be coated with powders or oils that don't react with the metals that they shape, roll forming can shape metals without affecting surface properties. This makes it an ideal shaping method for polished metals, coated metals and other metals whose aesthetic properties must be maintained. 
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Roll Formed Part Types

  • Aluminum angles are bent or conjoined pieces of aluminum that form an angle.
  • Aluminum channels are open or closed rectangular tubes made of aluminum. 
  • Angle irons are bent or conjoined pieces of heavy-duty metal that are often used to support a structure.
  • Angles are created by roll forming various metals, commonly stainless steel, and provide support in two directions. Angles often contain holes or slots for connecting parts, which increases strength and firmness.
  • Channels provide a support system for numerous roll formed products, such as frames and rails.
  • Custom roll forming is a roll forming service that offers the fabrication of custom products.
  • Metal channels are roll-formed products that provide a support system frames and rails.
  • Metal rings are circular, roll-formed parts used to join and seal.
  • Metal trim fits around the edge of a product or part.
  • Metal wall panels are sheets of roll formed metal that are used to cover walls.
  • Outboard mills are roll forming machines which have housings that support both ends of the roll tooling shafts.
  • Post-cut roll forming is a process that uses continuous rolls of metal and does not cut the piece to size until after it has been roll-formed. This process is the most common, efficient, consistent and least troublesome roll forming method.
  • Pre-cut roll forming is a process that uses material that has been cut-to-length before entering the roll forming machine. This method is primarily used for low-volume applications.
  • Roll formed products are metals that have been passed through a series of rollers in order to take on a shape. 
  • Roll formers are machines that are used to roll form metals.
  • Steel angles are roll-formed products made by bending a piece of steel sheet metal.
  • Steel channels are roll-formed products made of steel that provide a support system frames and rails.
  • Rings are often roll formed from other shapes and commonly function as container seals and lids. Stainless steal is the preferred alloy.


Roll Formed Part Terms

Accumulator - Piece of equipment that holds metal coil so the roll forming process may continue uninterrupted while new material is attached to the coil.

Auxiliary Operations - Secondary processes performed in conjunction with roll forming.

Camber - A deviation from a straight line in a roll formed piece.

Coiling
- Procedure in which heated flat sheet metal is transformed into spiral coils.

Cold Work - The process of deforming metal at room temperature in order to increase strength and hardness.

Drive System - The system responsible for providing the roll forming machines with power and moving the metal coils through the machines.

Ductility - The ability of metal to bend or form without fracture.

Elastic Limit - The maximum amount of stress a metal can accept without succumbing to permanent deformation.

End Flare - Deformation at the end of a roll formed part.

End Joiner - Piece of equipment that connects two coils to permit the continuance of metal coils into the roll forming machine.

Ferrous Metal - A metal in which iron makes up a significant component.

Levelers - Mechanism that maintains flatness of metal being fed into the roll forming machine.

Nonferrous Metal - A metal that does not contain iron.

Plastic Deformation - Permanent changes in the shape of a metal that occur after pushing a metal piece past its elastic limit. Deformation is accomplished through the application of stress.

Pickling - The process of cleaning steel coils in preparation for metal forming processes, such as roll forming. The coils are subjected to hydrochloric acid that removes impurities, such as rust, from the metal.

Reel Kinks - Imperfections in the metal coil.

Roll Changing - The process of changing the rolls on roll forming equipment. This is a long, costly procedure.

Slit Edges - In reference to the edge of sheet or strip metal that results from cutting to width by rotary slitters.

Springback - Deformation in a roll formed part that occurs when the roll forming process fails to stretch a part past its elastic limit.

Sweep - Deviation from a straight line in the horizontal plane measured after the part has been formed. Sweep is caused because of incorrect horizontal roll alignment and/or uneven forming pressure.

Tolerance - The acceptable variation from product specifications, such as cross-sectional dimensions.

Trimming - Removing metal scrap from a metal formed part in order to maintain consistency among metal parts.

Twist
- Deformation in a roll formed part that resembles a corkscrew. Twists are caused by extreme pressure levels created during the roll forming process.

Yield Strength - The maximum stress which can be applied to a material without lasting deformation of that material.




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