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:Â 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:Â 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:Â 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

How Custom Roll Forming Contributes to Sustainable Manufacturing Practices
The manufacturing industry has become increasingly aware of its environmental impact, and as a result, businesses have started to adopt sustainable manufacturing practices to reduce their carbon footprint and minimize waste production. Sustainable manufacturing emphasizes the responsible use of resources, energy efficiency, and waste reduction, leading to long-term benefits for companies and the environment. Custom […]

The Impact of Material Selection in the Roll-Forming Process: Steel vs. Aluminum
Material selection is a critical factor in the success of any manufacturing project, and this is especially true in the roll forming process. The choice of material can significantly impact the performance, functionality, and cost of the final product, making it essential for manufacturers to carefully evaluate their options in this regard. At Roller Die […]

Enhancing Customer Experience with Roller Die + Forming’s In House Engineering Team
In today’s highly competitive market, businesses must continually seek ways to optimize production processes, reduce costs, and improve the customer experience. In the realm of custom roll forming, this often means finding a trusted partner who can offer not only high-quality, competitively priced products but also technical expertise and engineering support. At Roller Die + […]
- « Previous
- 1
- 2
- 3
- 4
- Next »