Commercial Roll Formed Products: A Guide to the Best Materials

From the humble carbon steel to the luxurious copper, roll formed products come in various metals, each with unique properties and benefits. 

But with so many options, which metal should you use for your project?

To help you out, we've put together a quick guide to the most popular metals used in roll formed products, comparing their:

• Formability
• Strength
• Cost
• Outdoor use
• Looks

Whether you're building solar panel racking mounts or designing power distribution systems, this guide will help you choose the perfect metal for your roll formed parts.

Popular Metals in Commercial Roll Formed Products

Metal roll formed profiles can be created using various materials. Here’s a look at some common materials used by metal roll forming companies:

• Carbon/Alloyed Steel
• Stainless Steel
• Aluminum
• Copper, Brass, Bronze

Once you combine and consider all these factors, you’ll be able to make the best decision for your roll formed part.

Carbon/Alloyed Steel Roll Forming

Sometimes designers specify carbon content in these steels to improve strength or formability.

Formability: High-strength alloyed steels have unusual properties and springback that create challenges for roll formers. In some cases, your manufacturer must overbend by 25 degrees or more to achieve a 90-degree bend. Mild steels, with carbon content not exceeding about 0.20%, are easy to form and weld. Steels with higher carbon content (about 0.4% to 1.0%) can’t be welded with the usual processes but can receive heat treatment. 

Strength: Many alloyed steels are extremely strong. The hardness and strength of mild steel cannot be increased by heat treatment. Steels with higher carbon content have better yield and strength. 

Cost: A thin, inexpensive carbon steel can take up just 40-50% of your part cost. Controlling the chemical composition costs vendors more, so buyers must pay more for metal whose chemical composition has been specified.

Outdoor Use: Because it’s the most affordable of the metals we’re discussing today, galvanized steel sees heavy use outdoors. But some lighter zinc coating galvanized surfaces don’t offer the same protection as stainless or copper; they’re best for indoor use. If yours is an outdoor project, make sure you’re using the best exterior metal grade.

Looks: Carbon steel isn’t pretty. If looks matter to your project, look elsewhere. Powder paint and liquid paint coating are common to protect carbon steel. You will get protection and the exact color you want while taking advantage of the low cost of plain carbon steel. 

Other: Steel is heavy. If portability matters to your project, try a lighter metal like aluminum.

Roll Forming Stainless Steel

Stainless steels have mid-range heaviness and come in a large variety. Their properties vary greatly based on alloying elements, heat treatment, and more.

Formability: Most stainless steel can be formed similarly to carbon steel, but consider its hardening properties and high springback when making your design. Stainless steel typically falls into one of three major classes:

• Austenitic stainless steels are ductile, but work hardening limits forming. The most commonly used alloys of this group are 304 and 316.
• Ferritic. Some 400 series types have limited ductility and, therefore, restricted formability. Some alloys work harden quickly, and it’s tough to weld them.
• Martensitic. This steel — except for 403, 410, and 414 — cannot be cold formed.

Strength: The strength and corrosion resistance of stainless steel often make it the material of choice in guns, engines, and other transportation equipment.

Cost: More expensive than carbon steel and aluminum, stainless reaches up to 80% of your total price. Unfortunately, the extra power your vendor must use to form stainless steel increases your labor costs. Roll forming stainless steel is still cheaper than luxury metals. Ferritic 400 metals are cheaper than 300s.

Outdoor use: Stainless steel is desirable for outdoor commercial and industrial purposes. Why? See the next paragraph.

Looks: Who doesn’t love stainless steel’s clean look?  Its chromium oxide layer is what makes it shine so beautifully. Stainless steel has a high percentage of chromium and other elements, making it resistant to staining, rust, some caustic materials, and heat. It does require occasional cleaning. Stainless steel also comes in a variety of brushed and polished surface finishes.

Other: Stainless steel is hygienic since it’s resistant to abrasion and easy to clean -- perfect for hospitals and labs where sterility is crucial.

Roll Forming Aluminum

First off, don’t specify your material simply as “aluminum.” There are numerous aluminum alloys, and their properties vary greatly based on alloying elements, heat treatment, etc. The 3000 series of alloys, such as 3003, 3004, and 3105, are the most popular.

Formability: Overall, roll forming aluminum is not as difficult for your vendor as roll forming steel. It’s soft and malleable. Most aluminum shapes are extruded but if you would like to use a sheet thickness below 0.06”, roll forming is your best bet.

Strength: Aluminum is generally strong, including mid-high tensile strength. As aluminum oxidizes, it creates a layer around itself. Manufacturers can force this via anodizing, immediately strengthening the metal. However, since aluminum types are all over the map in terms of characteristics, make sure you grab the right grade.

Cost: Reasonable.

Outdoor use: Aluminum is typically not designed to last for a long time outdoors.

Looks: Aluminum will oxidize. Notably, aluminum doesn’t need a protective coating -- anodizing leaves it with a polished finish.

Other: Aluminum is lightweight and easily transportable.
 

Copper, Brass, Bronze Roll Forming

Copper features prominently as a primary component in other nonferrous alloys. Brass is a copper and zinc alloy featuring a bright, gold-like color. Bronze, a type of brass, is an alloy of copper and tin.

Formability: Copper is a ductile metal. More ductility means easier roll forming for your vendor, which means better odds of success. Brass is very malleable and versatile. When it comes to architecture, red metals, and aluminum are the most common nonferrous materials. They are the easiest to manipulate into designs.

Strength: The “red metals” maintain strength after being formed. These metals are equivalent to stainless steel in resilience or form, but not as strong structurally. They are incredibly durable and they’re immune to the elements once oxidized.

Cost: They are called luxury metals — so you’re correct if you guessed they are quite expensive.

Outdoor use: The metals feature prominently in building materials. They can last hundreds and hundreds of years.

Looks: They’re best for applications in which beauty counts. With a red metal, your project will stand out. Brass, for one, has a bright, gold-like color and a high corrosion resistance. But be aware that red metals turn somewhat green if they oxidize.

Other: If these metals’ prices are unrealistic for you, clad your part instead.

Here is a summary of the properties of each metal:

Commercial Roll Formed Products: Let’s Summarize Your Needs

Roll Formed Products: Let’s Summarize Your Needs

Ask yourself when requesting roll formed products:

• “What is my budget?”
• “Are looks important?”
• “Does my project need to hold up against tough conditions?”
• “Is my project structural or otherwise needing a strong metal?”
• “Is it worth requesting a metal grade that’s difficult to form to get the features I need or am I just wasting resources?”

Knowing the answers to these questions will help you decide which metal to use for your roll formed products. 

For more information, download our free guide on designing a great roll formed part:

(Editor’s note: This article was originally published in September 2017 and has recently been updated.)