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
Optimizing Supplier Locations
When you’re considering different suppliers for custom roll formed metal parts, one factor to take into consideration is the location of the supplier and related logistics of transferring parts from the supplier’s facility to yours or to the installation location. With locations across the southeast US and in central Mexico, Roller Die + Forming is […]
Mixing Standard and Custom Tooling
To create roll formed metal shapes, we use specially-designed rollers that bend the strip metal incrementally until the correct cross-section is achieved. These rollers, along with pre-punches, presses, and cut-off dies, are part of the tooling that is necessary to create a part. Each time your part is run at Roller Die, this tooling must […]
Solar Carports and Covers
Solar carports are one of those obviously really good ideas and they are starting to pop up across the country, shading cars and keeping them cool during the day while providing energy to power buildings and even those same cars. In areas of the country where solar is a strong source of alternative power, solar […]
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