Extrusion Services

Roll Forming Parts for Manufacturers - Custom Roll Formed Parts

Aluminum Extrusion vs. Roll Forming

Challenge:ย 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:ย 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:ย 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 Works to Expand Capabilities

Roller Die Works to Expand Capabilities

By Roller Die + Forming |

The management team at Roller Die + Forming is always willing to invest in equipment to help meet customer demand. This means upgrading machinery to run faster, maintain our in-house tooling so that it holds tight tolerances, and occasionally purchasing new roll lines to run new thicknesses and calibers of material. From solar racking to […]

Explore the Roller Die + Forming Plant in Green Cove Springs, FL

Consider the Financial Strength of Your Suppliers

By Roller Die + Forming |

When choosing a business to supply parts, there are a number of important factors to review, especially if the suppler-vendor relationship will be ongoing. The first consideration is always whether the supplier can meet the needed specifications. When you work with Roller Die + Forming, our sales team will help you interface directly with our […]

Large Volume Custom Roll Forming: DIY or Outsource?

Large Volume Custom Roll Forming: DIY or Outsource?

By Roller Die + Forming |

When it comes to customers who need large volume custom roll forming services, we often find that they try to do it in house first. They buy the roll forming machines, source the raw materials, and train staff on how to run the machines. Over time, they often end up at our door because, while […]