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
Supporting the Roller Die Family
What do you do when you find out your sister is fighting cancer? Well, there are lots of things, but for Keith Zimmerman, at Roller Die + Forming in Louisville, it included getting his coworkers to shave their heads in support and take a picture to lift her spirits. “Tracy’s really been a champ about […]
Roll Forming Supports Green Jobs
We often talk about how roll forming is a lean, green, low waste, and sustainable process for creating custom metal parts. At Roller Die + Forming, many of the parts we make go on to support the infrastructure and projects that are at the heart of green jobs. Green jobs is a movement focusing on […]
Amortizing Roll Form Tooling
Custom roll form tooling is often necessary to create the exact cross section or hole punch pattern clients desire. A well-designed custom cross section or multi-pattern hole punch can create many different parts, so is often worth the up-front investment in the cost of tooling. The Roller Die + Forming engineering team is experienced in […]