Metal Forming Processes: Techniques, Industries, & Use Cases

Metal forming processes are an essential part of our society, and without them, our society would come to a grinding halt.

The products and components created by the different metal shaping techniques are used in creating everything from scaffolding and heavy machinery, to designing and creating microprocessors and artificial intelligence. 

When it comes to metal forming, there are several processes to choose from, with each offering its own list of benefits and detriments, each suited to certain applications, and each suited for different types of metal.

Some of the most common types of metal forming techniques are:

1. Roll forming
2. Extrusion
3. Press braking
4. Stamping
5. Forging
6. Casting

Let's explore some of the common applications that each type is used for, as well as some of the industries that use each type.

1.  Roll Forming

In short, roll forming involves continually feeding a long strip of metal through drum rollers to attain a desired cross-section.

Some general notes about roll forming that you should be aware of:

1. Allows for advanced inline addition of punched features and embossings
2. Is best suited for large volumes
3. Yields complex profiles with intricate bending
4. Has tight, repeatable tolerances
5. Has flexible dimensions
6. Can be cut to any length
7. Requires little tool maintenance
8. Is capable of forming high-strength metals
9. Permits ownership of tooling hardware
10. Reduces room for error
11. Creates less scrap
    
    

Common Applications & Industries

Industries

• Aerospace
• Appliance
• Automotive
• Construction
• Energy
• Fenestration
• HVAC
• Metal Building Products
• Solar
• Tube & Pipe

Common Applications

• Construction Equipment
• Door Components
• Elevators
• Framing
• HVAC
• Ladders
• Mounts
• Railings
• Ships
• Structural Components
• Tracks
• Trains
• Tubing
• Windows

2.  Extrusion

Extrusion is a metal forming process that forces metal through the die of a desired cross section.

If you're thinking of pursuing extrusion metal forming, you should keep in mind that:

1. Aluminum is primarily the extrustion of choice, though most other metals can be used
2. Dies (aluminum) are relatively affordable
3. Punching or embossing done as a secondary operation
4. It can produce hollow shapes without seam welding
5. It can produce complex cross-sections
   
   

Common Applications & Industries

Industries

• Agriculture
• Architecture
• Construction
• Consumer Goods Manufacturing
• Electronics Manufacturing
• Hospitality
• Industrial Lighting
• Military
• Restaurant or Food Service
• Shipping & Transportation

Common Applications

• Aluminum Cans
• Bars
• Cylinders
• Electrodes
• Fittings
• Frames
• Fuel Supply Lines
• Injection Tech
• Rails
• Rods
• Structural Components
• Tracks
• Tubing
  
  

3.  Press Braking

Press braking involves bending sheet metals (usually), forming the metals to a predetermined angle by pinching it between a punch and a die.

If you're interested in press braking, be aware that it:

1. Works best for shorter, smaller runs
2. Produces shorter parts
3. Is best suited for compatible shapes with more simple bend patterns
4. Has a high associated labor cost
5. Produces less residual stress than roll forming
   
   

Common Applications & Industries

Industries

• Architecture
• Construction
• Electronics Manufacturing
• Industrial Manufacturing

Common Applications

• Decorative or Functional Trim
• Electronics Enclosures
• Housings
• Safety Features
  
  

4.  Stamping

Stamping is the process of placing a flat sheet (or coil) of metal into a stamping press, where a tool and die apply pressure to form the metal into a new shape, or cut out a piece of the metal.

Stamping is associated with:

1. Single-press stroke forming
2. Consistent pieces with fixed dimensions
3. Shorter parts
4. Higher volumes
5. Creating complex parts in a short amount of time
6. Requiring high-tonnage presses
   
   

Common Applications & Industries

Industries

• Appliances Manufacturing
• Construction
• Electrical Manufacturing
• Hardware Manufacturing
• Fastenings Manufacturing

Common Applications

• Aircraft Components
• Ammunitions
• Appliances
• Blanking
• Electronics
• Engines
• Gears
• Hardware
• Lawn Care
• Lighting
• Lock Hardware
• Power Tools
• Progressive Die Stamping
• Telecom Products
  
  

5.  Forging

Forging involves shaping metals using localized, compressive forces after heating the metal to a point where it's malleable. 

If you're considering forging, keep in mind that:

1. Precision forging combines production and manufacturing by forming the raw material into the desired shape, with the lowest possible amount of secondary operations needed
2. It requires little to no subsequent fabrications
3. It requires high tonnage presses
4. It yields a tougher end product
5. It results in a product with high strength and hardness
   
   

Common Applications & Industries

Industries

• Aerospace
• Automotive
• Medical
• Power Generation & Transmission

Applications

• Axle Beams
• Ball Joints
• Couplings
• Drill Bits
• Flanges
• Gears
• Hooks
• Kingpins
• Landing Gear
• Missiles
• Shafts
• Sockets
• Steering Arms
• Valves
  
  

6.  Casting

Casting is a process that involves pouring liquid metal into a mold, containing a hollow cavity of the desired shape. 

Those considering utilizing a casting metal forming process should keep in mind that it:

1. Can use a large range of alloys & custom alloys
2. Results in affordable short-run tooling
3. Can result in products with high porosity
4. Is best suited for smaller runs
5. Can create complex parts
   
   

Common Applications & Industries

Industries

• Alternative Energy
• Agriculture
• Automotive
• Construction
• Culinary
• Defense & Military
• Health Care
• Mining
• Paper Manufacturing

Common Applications

• Appliances
• Artillery
• Art items
• Camera Bodies
• Casings, Covers
• Diffusers
• Heavy Equipment
• Motors
• Prototyping
• Tooling
• Valves
• Wheels
  
  

Choosing A Metal Forming Technique

The type of metal forming process that you should choose will depend on many factors: What metal are you working with? What's your budget? What do you need created, and what will it be used for?

Each meal forming method has distinct advantages and disadvantages, and each is better suited for different metal types and applications. If you believe roll forming might be the way to go, the free, downloadable e-book below is a great place to get started.

(Editor's Note: This article was originally published in January 2017 and was recently updated.)