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.

Roller Die + Forming News & Articles

Building a Strong Foundation

Building a Strong Foundation: Custom Roll-Formed Products in Construction

The construction industry is constantly on the lookout for innovative materials and methods that enable more sustainable, efficient, and cost-effective building projects. Custom roll-formed products are poised to significantly contribute to this transformation, offering customized and high-quality solutions across diverse applications.  In this article, we will delve into the benefits of incorporating custom roll-formed products […]

Solar Energy

Empowering Solar Energy with Custom Roll-Formed Products

The solar energy industry continues to experience rapid growth as countries and consumers seek clean, renewable sources of power. To maintain this momentum and enhance efficiency and effectiveness, solar equipment requires innovative manufacturing solutions that ensure quality, durability, and affordability.  Custom roll-formed products offer a unique and versatile approach to providing essential components for solar […]

Solar Energy

Powering Solar Energy Advancements: Custom Roll-Formed Products for Sustainable Solutions

The solar energy industry is expanding at an unprecedented rate to meet the increasing global demand for clean and sustainable energy sources. For solar installations to be reliable, efficient, and cost-effective, high-quality components are essential. Custom roll-formed products play a crucial role in supporting solar installations by providing tailored, durable solutions for various applications.  We […]