Extrusion Services

Roll Forming Parts for Manufacturers - Custom Roll Formed Parts

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.

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Roller Die + Forming News & Articles

Roller Die Creates Tooling for Aluminum Angles

Roller Die Creates Tooling for Aluminum Angles

By Roller Die + Forming |

Steel isn’t the only material that can be easily roll formed. Aluminum is another excellent option for parts where weight and flexibility are key. Parts made from various different grades and finishes of aluminum are great for applications where structures move and flex and weigh much less than a comparable part made from steel. Transportation […]

Planning for Steel Mill Outages to Avoid Material Shortage

Planning for Steel Mill Outages to Avoid Material Shortage

By Roller Die + Forming |

Roller Die customers are encouraged to place orders for the coming months as soon as possible. Steel mills across the country are reporting outages for various reasons, driving up the costs of raw material and the time to receive that material. While most of the outages are due to scheduled equipment maintenance, unplanned outages are […]

The Benefits of Cold Roll Forming vs Hot Roll Forming

7 Reasons Roll Forming is More Efficient

By Roller Die + Forming |

Roll forming is a process that involves passing coiled sheet metal through a horizontal series of rotating dies to produce the desired shape. This method offers a flexible and cost-efficient process of shaping metals into different shapes or custom cross-section profiles. Roll forming is superior to other metal forming processes, and it is used in […]