Extrusion Services

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Aluminum Extrusion vs. Roll Forming

Challenge: A potential customer found the RDF website through an Internet search. After a review of our extensive capabilities, an inquiry was submitted for assistance with a complete conveyor system redesign.

This customer wanted to convert a very costly aluminum extrusion system to a much more manufacturing friendly roll formed system, produced in a quarter-hard stainless steel. With the current supply chain for this system located in Europe, the customer focus was on a two-fold cost reduction initiative: roll formed shapes of the highest quality, produced in the US (roll forming shapes vs aluminum extrusion).

Solution: Through numerous conference calls and concept design sessions, we were able to develop a concept consisting of just a single roll formed shape.

This easily roll formed shape could be mirrored back-to-back, utilizing any two parts yielded at the production line. These two parts would then be spot welded together down the length of the part. This process essentially replicated the tightly toleranced aluminum extrusion design, but at a fraction of the price. Additionally, the strict quality standards Roller Die implemented and repeatability were maintained on critical parts where consistency is the key to success.

Result: The lower cost solution has since paved the way for a much more price-competitive system in the marketplace, and sales for this system have seen substantial growth over the past year. Currently, we are working with this customer on a new project of similar scope, and are continuing to build a solid, long-term customer relationship, while also still providing those win-win solutions.

Our Aluminum Extrusion Capabilities

At Roller Die + Forming, we offer Aluminum Extrusion services. Our team of experts can handle virtually all types of aluminum extrusion to your unique requirements. We use the best tools and processes to achieve accurate and highly durable parts, with no room for inconsistencies. From prototype to production, Roller Die + Forming remains your reliable partner for your various extrusion needs.

Roller Die + Forming News & Articles

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Rapidly growing custom metal forming company Roller Die expands Louisville, KY staff, adding and expanding in several key roles.

LOUISVILLE, KY, April 26, 2022 – Louisville-based custom metal part manufacturer Roller Die + Forming recently added to their talent pool in the corporate headquarters with several new business development and support roles. With over 100% growth over the last ten years and the increasing demand for American suppliers, Roller Die management knows that bringing […]

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New 2.5″ Roll Form Line Installed in Queretaro, Mexico

Recently, the Roller Die + Forming plant in Queretaro, Mexico, acquired a 2 1/2″ (2.5″) line to add additional capabilities to the location. This line gives the Mexico location greater capacity and gives our customers more options. Specifically, the new line can handle parts that are 0.079″ to 0.140″ thick, which is thicker than many […]

Roll Forming Dies and Tooling Library

When You Might Need Custom Tooling

At Roller Die + Forming, we’re justifiably proud of our huge inventory of standard tooling. We’re able to make a lot of complex shapes and help our customers keep costs low with this excellent variety. However, there are many times customers still want us to create custom tooling and several advantages in doing so. Truly […]