Custom Roll Forming Solutions for the Aerospace Industry: Enhancing Performance and Reliability


The aerospace industry is one that demands the highest level of precision, reliability, and performance. There is no room for error when it comes to the materials and components used in aerospace manufacturing. Custom roll formed products are an invaluable resource for aerospace manufacturers and engineers, providing high-quality, durable, and lightweight metal components that can meet and exceed the exacting requirements of this rapidly evolving industry.

Roller Die + Forming, a leading supplier of premium custom roll formed products, has established itself as a trusted partner for the aerospace industry by offering tailored, high-performance metal components that address the unique demands of aerospace applications. Our advanced roll forming processes produce top quality, high-strength components that are not only competitive in price but also maintain the strict safety and integrity standards essential for aerospace manufacturing.

There are many applications and benefits of custom roll formed products in the aerospace industry which contribute to greater efficiency, safety, and innovation in aerospace design and manufacturing.

Custom Roll Forming Solutions for the Aerospace Industry: Enhancing Performance and Reliability

Advantages of Custom Roll Formed Components for Aerospace Applications

Custom roll forming offers numerous benefits that align perfectly with the stringent demands and exacting requirements of the aerospace industry:

  1. Weight Reduction: Custom roll formed components provide lightweight solutions for aerospace structures without compromising strength, contributing to improved fuel efficiency and overall performance.
  2. Customized Engineering: Roll formed components can be precisely tailored to specific aerospace applications, ensuring optimal design integration, structural integrity, and streamlined manufacturing processes.
  3. High-Strength Materials: The use of advanced high-strength materials in custom roll forming, such as aerospace-grade alloys, enables the production of components that meet and exceed rigorous safety and performance standards.
  4. Cost Efficiency: The roll forming process is recognized for its cost effectiveness, making it an attractive option for aerospace manufacturers looking to reduce production costs without sacrificing quality or performance.

Applications of Custom Roll Formed Components in Aerospace Manufacturing

Custom roll formed components have a wide range of applications within the aerospace sector, including:

  1. Aircraft Structures: Custom roll formed products can be used to construct various parts of aircraft structures, including fuselage frames, wing spars, and bulkheads, offering lightweight yet durable solutions that enhance overall performance.
  2. Interior Components: Roll formed components play an essential role in aircraft interiors, providing high-quality components for seating, overhead storage, and cabin dividers that optimize weight and strength without compromising aesthetics.
  3. Reinforcement Elements: Custom roll formed products can be utilized for reinforcement elements such as longerons, stringers, and stiffeners, which provide increased structural rigidity and help maintain the integrity of the aircraft structure.
  4. Engine and Avionic Components: Roll forming enables the production of cost-effective, high-performance engine and avionic components, including heat exchangers, exhaust components, and electronic enclosures.

Material Selection for Aerospace Roll Formed Components

The choice of materials for custom roll formed components plays a critical role in their performance and durability within the aerospace context:

  1. Aerospace-Grade Aluminum: Aerospace-grade aluminum alloys are known for their lightweight and high-strength properties, making them a preferred choice for many aerospace applications, including structural components and heat exchangers.
  2. Titanium: Titanium’s exceptional strength-to-weight ratio, resistance to corrosion, and high temperature capabilities make it an ideal material for aerospace components such as engine components and landing gear.
  3. Stainless Steel: Stainless steel offers excellent corrosion resistance and high strength, making it suitable for aerospace applications that require enhanced durability, such as exhaust systems and fasteners.
  4. Nickel Alloys: Nickel alloys, such as Inconel and Hastelloy, provide exceptional high-temperature performance and corrosion resistance, making them an ideal choice for engine and exhaust components in aircraft and aerospace systems.

Quality Control and Standards Compliance in Aerospace Roll Forming

Adherence to strict quality control standards and compliance with industry-specific regulations are paramount in the aerospace sector, ensuring the reliability, safety, and performance of custom roll formed components:

  1. Quality Management Systems: Implementing a robust Quality Management System, such as ISO 9001, ensures that roll forming processes meet the high standards demanded by the aerospace industry.
  2. Material Traceability: Maintaining strict material traceability throughout the manufacturing process helps ensure that custom roll formed components comply with aerospace specifications and standards.
  3. Non-destructive Testing (NDT): The use of NDT techniques, such as radiographic testing and ultrasonic inspection, is essential for verifying the integrity and reliability of custom roll formed components in aerospace applications.
  4. Documentation and Certification: Comprehensive documentation and certification of materials, processes, and finished components provide aerospace manufacturers and engineers with assurance of the quality and compliance of custom roll formed products.

Elevating Aerospace Performance with Custom Roll Formed Solutions

As the aerospace industry continues to push the boundaries of what is possible in terms of performance, safety, and innovation, custom roll formed components are poised to play an increasingly significant role in supporting this progress. Roller Die + Forming’s expertise in providing tailored, high-quality roll formed solutions allows aerospace manufacturers and engineers to access the benefits of lightweight, durable, and cost-effective metal components specifically designed to meet the unique challenges of their industry.

Trust Roller Die + Forming to deliver custom roll formed solutions that meet and exceed the exacting standards required in the aerospace industry, helping to propel your projects to new heights of success.