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: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.
Roller Die + Forming News & Articles

Roller Dieโs Standard Tooling Library
Our sales team likes to talk about the Roller Die Standard Tooling Library because it provides a huge value to our customers. Over the last 60 years, our in house tool room has created a large collection of standard size and shape tooling. We can use this tooling to run jobs that fit these sizes […]

Roller Die Helps Mobile Home Industry
Roll forming can be used in a wide variety of industries and is often a much better option than using standard steel shapes and parts. We recently worked with a client in the mobile home industry to help them cut costs, cut waste, and produce a better part for their process. Similarly, weโve worked with […]

Roll Forming is All About Speed
Speed is the theme of the year for 2020, but what does that mean for roll forming and what can the Roller Die + Forming customers expect? Like most manufacturing operations, it means we will be taking steps throughout the year in each department to increase our speed and performance while not sacrificing quality. For […]
- « Previous
- 1
- …
- 4