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 + Forming rolls custom parts for Santa's Big Workshop

Roller Die + Forming rolls custom parts for Santa’s Big Workshop

By Roller Die + Forming |

Rapidly growing custom metal forming company Roller Die works with the elves at Santa’s Workshop to make custom racking and automated storage and retrieval systems. NORTH POLE, December 25, 2019 — Santa’s Workshop awards Roller Die + Forming with award for being a top supplier and working on their warehouse upgrade project. Roller Die supplied […]

Growth in Custom Metals Leads Roller Die + Forming to Appoint New COO

Growth in Custom Metals Leads Roller Die + Forming to Appoint New COO

By Roller Die + Forming |

Rapidly growing custom metal forming company Roller Die promotes industry and company veteran Chris Kovacs to newly created COO position. LOUISVILLE, KY, December 9, 2019 — Over the past ten years, custom metal former Roller Die has grown over 100% and aims to continue that growth. As part of running a growing company, management created […]

Rapidly Growing Custom Metals Manufacturer Roller Die + Forming adds talent to their existing team with a new CFO, Kent Houserman, CPA.

Rapidly Growing Custom Metals Manufacturer Roller Die + Forming adds talent to their existing team with a new CFO, Kent Houserman, CPA.

By Roller Die + Forming |

Rapidly growing custom metal forming company Roller Die hires new CFO Kent Houserman, CPA. LOUISVILLE, KY, December 9, 2019 – Louisville-based custom metals manufacturer Roller Die + Forming recently added to their talent pool of executives, hiring Kent Houserman, CPA to fill the CFO position. With over 100% growth over the last ten years and […]