5 Expert Tips for Designing the Worst Roll Formed Parts Ever

Who wants to make great roll formed parts? Not you, obviously. Optimization is so boring. You’re a trailblazer, a forward thinker -- and that means going against the grain. Breaking tradition.

That’s what we like to see. To help you out in your innovative efforts, we've put together some tips to design the crappiest roll formed part you’ve ever seen.

(This information is based on over 100 years of experience. It’s guaranteed to ruin your roll formed parts. Good stuff.)

5 Sure-Fire Ways to Ruin Your Roll Formed Parts

1.  Super Tight Tolerances

That’s right. Get those babies nice and tight. The goal here is to strangle your manufacturer’s process and create as much waste as possible. After all, a component off the mark by 0.001” is unacceptable.

2.  Make Your Component Out of Space Metal

Only the rarest metals will do for your basic structural components. The more difficult it is to obtain, the better!

Oh, and don’t forget to choose the least ductile metals possible - that makes it extra difficult for your manufacturer to roll form your parts.

3.  Punch Holes Directly on Bends

Who needs perfect circles? Holes near bends stretch into pretty little egg shapes. Oval is the new round.

Alternatively, place holes directly on the edge of your part. You’re aiming for maximum distortion!

4.  Leggy

Extreme, flat leg lengths are your friend. Whether short and stubby or giraffe-like in their tallness, your goal is to make proper forming as difficult as possible. Your manufacturer is certain to struggle to fulfill this requirement!

(Unless they have MeshTrim. In which case, try harder.)

5.  Tight Corners

Preferably, less than 1-½ times material thickness. You want to drive up operating costs as high as possible - tight corners are a great way to increase tool wear, breakage, and burn out a low-horsepower roll forming machine.

Tight corners can also cause stress cracking in harder materials (which, yours should be very hard, as per #2 above). Two birds with one stone! ...Literally, since your single part may break into two parts during use.

Worried Your Roll Formed Parts Aren’t Bad Enough?

Don’t worry - we’ve got you covered. Download this guide on How to Design a Great Roll Formed Part, and simply do the opposite of what it says!

It’s super easy to design a terrible roll formed part. Just trust in your innate human ability to cause chaos. You can do it!