Along with steel, aluminum roll forming makes up a large portion of Roller Die’s business. Our engineers understand when aluminum is preferable for a specific end product. Aluminum has approximately one-third the density of steel, which is often ideal for use in roll formed Aluminum Angles. Additionally, many end uses of Aluminum Angles demand a lighter metal, intended for structures that move. Another benefit of aluminum? All grades and finishes that are cold-workable at room temperature can be roll formed.

In addition, Aluminum Angles cater well to transportation vehicles — operating on Earth and beyond. These Angles and other roll formed shapes are especially active in the Aerospace, Automotive, Marine & Solar industries. Additionally, continued exploration of space and sea means Aluminum Angles will increase in popularity this century. Contact us to describe your upcoming Aluminum Angle project.

Aluminum can be roll formed into simple angles and more complicated cross-sections including hat channels, z-shapes, and even custom shapes designed to meet specific customer needs. Roller Die + Forming has significant experience in rolling aluminum. Our in-house tool room can make and maintain the rollers, punches, and cut-off dies used in rolling aluminum angles.

Customers can leverage Roller Die’s catalog of standard tooling to create a wide variety of shapes that meet their needs. Whether your project requires the lighter weight that aluminum angles bring to a project or need more movement than steel, aluminum is often a great option. Aluminum roll formed parts are found in trucks, appliances, solar racking, and many other parts.

When you reach out to a member of the Roller Die sales team, they’ll take the time to understand your project, your goals, and the end use of the part you’re looking to create. Our engineering team will work to quickly get you a quote for your aluminum angle or aluminum part and can work with your engineering team to create a part that meets your needs while taking advantage of our in-house tooling and in-line processes.

Once you’ve completed the prototyping process, we start sourcing the raw materials for your project. Because we purchase a large volume of metal, we have multiple sources and are able to secure good prices on our volume purchases. When we roll form aluminum angles, we are able to hold industry-standard tolerances in the angles of the cross section. For some applications, we’re able to hold even tighter tolerances than industry standard by using additional rollers.

roll formed aluminum anglesStandard Angle Part Dimensions


Aluminum Angles: Tolerance Capabilities

Cross-Sectional Standard Tolerances: +/-.031″
Angularity: +/- 1 degree
Straightness: Maximum Deviation of .015″/ft
Twist: Maximum Deviation of 1/4 degree per ft


Length Tolerances

Length up to 36″ : +/-.030″
Lengths 36″ to 120″ : +/-.060″
Length 120″ to 240″ : +/-.125″
Lengths greater than 240″ : +/-.250″
**Note: In some cases, closer tolerances than the standard (listed above) can be achieved, but may require additional tooling.

In-Line Processes:

aluminum angles roll formed

  • Pre- and Post-Process Hole Piercings
  • Inline Flying Cutoff Providing Parts Cut to Finished Length
  • Stampings
  • Welding
  • Secondary Punching +ACY- Forming Operations
  • Assembly
  • Special Packaging



In addition, Aluminum Angles are produced with All Types of Finishes, from Standard Commercial Quality Mill Finish to Bright Annealed and Mirror Finishes. Therefore, contact us and we’d be happy to adapt your specific needs.