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.
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.
Roller Die + Forming News & Articles
Driving Automotive Innovation with Custom Roll-Formed Products
As the global automotive industry moves at full speed toward more efficient, high-performing, and environmentally friendly vehicles, advanced materials and innovative manufacturing techniques play a pivotal role. Custom roll-formed products, with their precision engineering, lightweight properties, and cost-effectiveness, have the potential to significantly contribute to automotive design and manufacturing advancements. In this article, we will […]
Exploring the Environmental Benefits of Custom Roll Forming in Sustainable Construction
The construction industry is undergoing a transformative shift toward sustainability and eco-conscious practices, striving to reduce the environmental impact of buildings while promoting energy-efficient design principles. Custom roll forming, as a manufacturing process that delivers both precision and resource-efficiency, can play a pivotal role in driving the adoption of sustainable construction techniques. By aligning with […]
The Impact of Custom Roll Forming on the Aerospace Industry
In the highly competitive and technologically advanced aerospace industry, optimizing performance, efficiency, and durability are of paramount importance. To meet these demanding requirements, engineers and designers are continually seeking innovative manufacturing processes and materials that offer lightweight, strong, and reliable solutions. Custom roll forming, a state-of-the-art manufacturing technique that delivers high-quality metal components in various […]