The 4 Most Common Myths of Roll Forming Metal
January 01, 2016
To many, roll forming metal seems like a niche process, used only in limited situations to form steel profiles. Consequently, the process itself is not well-understood by the public, which means misconceptions develop and persist. We're here to clear the air and address those misconceptions directly.
Tooling for any kind of metal fabrication can be costly. If you buy smart, roll forming tools are no more expensive than any other type of tooling. Here are a few ways to mitigate high tooling costs:
In the case of Dahlstrom Roll Form, our one hundred years of experience comes with an archive of over 1,400 existing tool sets. We may already have tooling that will work for you, so you may not need to pay additional tooling costs at all.
Although high volumes are certainly the most cost-effective way to utilize roll forming, small and medium runs don’t have to break your bank.
First off, depending on your part design, volumes as low as 10,000 to 20,000 linear feet per year can be cost-effective.
Your manufacturer can also provide economic order quantity runs. These allow for inventory to be held by the manufacturer and distributed to you as needed. Economic runs maximize volume and reduce setup time, and you receive small as-needed deliveries.
Similar to offering discounted tooling in exchange for a long-term purchase commitment, your manufacturer may also be willing to discount your small roll forming orders in exchange for a longer-term contract.
Finally, roll forming may be the only realistic option for producing your part. In that case, it may not matter the cost - you’ll need to produce it anyway.
In any case, be sure to talk to your manufacturer about accommodations for your needs.
On the contrary, roll forming is quite precise as long as the manufacturer understands the quirks of the process.
Roll forming does produce end flare, and the metal will experience some springback. Your manufacturer should understand how these distortions can be controlled by part design, and the number of forming stations in the line.
Done correctly, roll forming can hold tolerances up to +/- 0.005” on certain profile segments. Overall part lengths can be accurate up to +/- 0.020”.
While steel is the most commonly roll formed material, any ductile metal (or non-metal!) can be formed with this process. This includes:
*Forming pre-painted steel will save you a secondary painting step. This helps to save on overall costs.
Pre-punched sheets that have gone through a turret punch press or a laser cutting center can be roll formed via hand-feeding of each sheet.
It can require a bit more maneuvering, but you don't need high volumes or loose tolerances to get your money's worth out of roll forming. On the contrary, companies who use roll forming are very satisfied with value and quality of roll formed parts.
Want to know whether roll forming is right for you? Give us a call. We're happy to chat!
Topics: OEM Roll Forming, Metal Fabrication, Myths, Materials, Roll Forming
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Since 1904, the Dahlstrom® name has been synonymous with an accepted standard of excellence in custom roll formed products. Over a century of consistent work in the roll form industry has left Dahlstrom® with a broad range of 1400+ unique profiles. If you are unable to find the shape you require in our catalog, Dahlstrom® can design & produce a new custom component that meets your specifications. Send us a Request for Quote today!
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