roll forming machine

Durability. Flexibility. Cost-effectiveness. Adaptability for a variety of industrial and commercial applications. You’ve probably wondered at some point how hot forming and cold forming compare in these categories. Although hot rolled steel shapes comprise the highest volume of rolled items in the United States, did you know that contract roll forming only uses cold rolling? So, to us, cold roll forming is just … roll forming. Hot rolling is basically nonexistent in the contracted OEM roll forming world. This process is left up to the steel mills making standard, commodity-type shapes. So, when it comes to hot forming vs. cold roll forming, what are the differences that make the cold process applicable and sometimes a better choice than hot forming? WHAT IS HOT FORMING VS. COLD ROLL FORMING? Hot Forming Hot forming is a combination of extruding and rolling using molten steel under extremely high temperatures. Some structural shapes, such as those used in holding up and reinforcing bui

There are plenty of other metals (besides steel) that are used for roll forming and other metal forming processes. Some of the most commonly used metals include: Aluminum Coated carbon steels Copper Bronze Brass Pre-painted coil steels Perforated metals A great engineering project always starts with the right metals -- so it’s wise to educate yourself on the pros and cons of each. Get it wrong, and you’re left with a needlessly expensive or low-quality product. It’s crucial to start your vendor on the right path instead! Let’s talk about the most important metals, then break them down into easy-to-follow categories of characteristics. (Don’t forget to scroll to the blue button below to download a full-sized PDF of all the key metals!) WHAT WE’LL COVER: ROLL FORMED STEEL & MUCH MORE Here are the metals we’ll cover in this chart: 1018 cold rolled steel Hot dipped G60 galvanized steel Hot dipped G90 galvanized steel A40 galvannealed steel A60 galvannealed steel 304 stainless steel 316

To many, roll forming metal seems like a niche process, used only in limited situations to form steel profiles. Consequently, the process itself is not well-understood by the public, which means misconceptions develop and persist. We're here to clear the air and address those misconceptions directly. DISPELLING THE 4 MOST COMMON MYTHS OF ROLL FORMING METAL 1.  Roll forming tools are too expensive. Tooling for any kind of metal fabrication can be costly. If you buy smart, roll forming tools are no more expensive than any other type of tooling. Here are a few ways to mitigate high tooling costs: If your manufacturer participates in part design, they may be able to save you money on tooling by optimizing the part for roll forming processes. Payments can be amortized over a period of time to avoid high up-front costs. Your manufacturer can discount or rebate the cost of tooling, in exchange for a commitment to buy a certain amount of parts over time. In the case of Dahlstrom Roll Form,

Charles P. Dahlstrom was an innovator who helped usher in a new era of architectural safety. As the industrial revolution seized America, more and more fires broke out due to the country’s lack of experience with its new technologies. Buildings were mainly constructed of wood and other flammable materials, with no legitimate means of slowing a fire once it started. It  was only a matter of time before someone stepped up with a solution. That someone was Charles P. Dahlstrom. You see, in 1904 Mr. Dahlstrom invented and introduced the world’s first fireproof door. Anticipating a large demand for his new product, Charles launched the Dahlstrom Metallic Door Company. He then aimed to corner the budding skyscraper industry by applying his fireproof technology to elevator entrances. Finally, to round out the Dahlstrom® product line, Charles created a series of decorative metal mouldings that would complement the elegant doors his company was already producing. All of these moves proved to be

If you’re interested in creative uses of architectural metal, look no further than HOK. They have many examples, but these are some of the most inspiring. HOK'S INSPIRATIONAL USES OF ARCHITECTURAL METAL 1.  Spire London Spire London is a “residential tower,” the definition of luxury apartment living. At 771 feet high, it currently stands as the tallest residential tower in Western Europe. It boasts bronze-colored metal detailing on the lower floors, with matching feature fins on its pavilion buildings. The design uses mixed materials, with metal complementing the traditional brickwork and elegant marble.   2.  University of Florida Research and Academic Center The UFRAC uses a mixture of metal mesh, glass, and a steel skeleton to create a beautiful and functional design. The mesh blocks many detrimental effects of direct sunlight, while allowing natural light into the building. HOK worked with GKD Metal Fabrics to realize this sharp design. The building is four stories with a multi

Will people remember your building after interacting with it? Or will they leave and immediately forget it? No designer wants their project to be forgettable. One way you can make your design memorable is to use high-quality materials in nontraditional ways. Architectural metals do that naturally -- they provide a strong visual impact while maintaining a durable design. Here are 8 ways to use metal to enhance the impact of your design. 1.  Create open spaces with less material Metal’s strength and low price point (depending on the material) make impressively high ceilings a simple design choice. It also allows for endless possibilities for non-traditional skeletal structures. 2.  Change aesthetics with decorative panels Embossed Textured Stamped Perforated Expanded Mesh Aside from their inherent beauty, different textures and thicknesses can create natural lighting effects as light hits the metal. 3.  Build gravity-defying structures Even the most delicately shaped metal structures res

Stainless steel outside? We all know it works well. But have you heard about 201 stainless steel? It’s a surprisingly nice metal for outdoor projects that require a blend of power, finesse, and beauty. Part of the 200 series of stainless steels, this metal is known for its use in indoor products like restaurant equipment, appliances, and cooking utensils. But 201 stainless will amaze you with its suitability for outdoor parts -- in automotive trim, architectural applications, grills, and more.   For a more generalized view of exterior metal choices, check this out. For more specifics on 201 stainless steel’s qualities, keep reading!   201 STAINLESS STEEL OUTSIDE: THE SPECS Cost: This grade of stainless steel’s relatively low cost is resulting in more frequent use among engineers and architects. Because it’s light in weight, you can pack in more per pound. Toughness: In certain applications (more on these in a sec), you need an extremely hard metal. Guess what’s extremely hard? 201 stai

Most people aren’t lucky enough to run a business in or live in an older building classically adorned with metal mouldings. As such, many folks feel like their home -- or commercial building -- is lacking distinctive architecture. Fortunately, designers can lean on a good architectural metal vendor to make a project sing -- and make your customers sing your praises. Boutique metal architecture is an underutilized element in today’s designs. The beauty and nature of metal can make for new and exciting products. Sometimes your brilliance just needs a good editor. Here’s how a partner can spark your innovative side with metal mouldings, creating a repeating image for your brand. WHY ADD ARCHITECTURAL METAL MOULDINGS? Metal accents come in numerous varieties. In the case of metal mouldings, that includes: Crowns Baseboards Chair rails Picture rails Mouldings open up rooms by taking advantage of light, contrast, and depth. They radiate quality, grace, and richness at a reasonable cost. Meta

Architectural design may be functional first and foremost, but it’s still a form of art. One aspect of art and analysis is motif. A motif is like a brand. It tells the viewer “I made this,” or “these designs are connected.” Your motif can be color, form, interior design components, or anything else. One of Frank Lloyd Wright’s design motifs was leaded glass windows. You don’t have to pioneer a design style to put a “signature” in/on your buildings. All it takes is one little component that belongs to you. Custom manufactured tooling can create that signature. CUSTOM MANUFACTURING FOR ARCHITECTURAL DESIGN While we’re most knowledgeable about roll forming tools, almost any manufacturing process can be customized to create a “signature” product. 1.  Full Ownership You own your custom tooling. It may sit in your manufacturer’s facility, but it belongs to you. You can request product from it at any time, and you don’t have to worry about tooling costs. It shortens lead times, and ultimately

What Is SMED? SMED stands for Single-Minute Exchange of Dies. As the name implies, the goal of SMED is to reduce die changeover time to under ten minutes. When setup times are long, manufacturers prefer to run as many pieces of possible. That doesn’t fit with kanban philosophy (smaller, frequent runs), so SMED aims to lower setup times to make small runs a viable option.   SMED Foundations 1.  Workplace organization Stopsign Everything has a place, and everything in its place. Tools should be available in their correct locations so you’re not scrambling for them during setup. Think of workplace organization like working in your kitchen: all your kitchen tools have their specific drawer, and if something is out of place it throws off your cooking game. It’s the same for manufacturers. If everything is taken from and put back in one designated spot, employees don’t have to hunt for tools, which cuts setup time significantly. 2.  Visual Management The purpose of visual management is to qu

“Which metals will get cheaper?” It’s a question OEM customers are asking even more these days in light of the latest events in the Section 232 investigation of unfair imports. It’s true that laws banning China and other countries from “dumping” their excess metal into the U.S. market could greatly impact your ability to do business in manufacturing. Let’s look at where domestic steelmakers are now and how they may soon have an easier time managing material cost and capacity. SECTION 232 INVESTIGATION RECAP The purpose of the U.S. government’s investigation is to determine the effect of steel and aluminum imports on national security. But the part you care about is whether its conclusion ends in tariffs or import quotas for foreign steel or aluminum. The U.S. Department of Commerce announced Jan. 11 it had completed its probe into imports and sent its conclusions to President Donald Trump. The climactic announcement ended up being anticlimactic, as the department gave no insight into t

Being ahead of the hottest trends is what makes an already qualified and experienced designer stand above the competition. As many modern upscale home and business owners seek to revamp their spaces with materials beyond wood, they are considering the use of strategically placed metal to create impressive architectural touches. An up-and-coming trend with architectural finishes involves a process called intentional corrosion (or forced corrosion). WHAT IS FORCED OR INTENTIONAL METAL CORROSION? Intentional corrosion of metal allows designers to take certain types of metal and transform them into vintage-looking pieces quickly. Want to get that orange-brown rusty finish or enjoy a lovely blue-green patina on your metal accents? There’s no need to stretch the design budget buying true antique pieces or waiting for nature to take its course if you are knowledgeable about the process of intentional corrosion. As a newer innovation in design techniques, requesting this rising trend can put y

durability, cost-effectiveness, and adaptability for a variety of industrial and commercial applications. While there certainly are some products that can be produced effectively through press braking, stamping, or extrusion processes, certain shapes where flat sheet is the raw material are best made through roll forming. Think of roll forming as the ability to make creations using an Etch-a-Sketch or drawn with your pen without lifting the tip from the paper. If you can envision your end product in this manner, there’s a good chance you can -- and will want to -- roll form it. If any of these elements are included in your profile design, definitely consider making them as a roll formed steel shape. 4 EFFICIENT ROLL FORMED STEEL SHAPES 1. Hems roll formed steel shapes hem roll formed steel shapes bendy Just like a seamstress makes a hem on fabric to provide an even finish, roll forming can be used to fold metal over 180° onto itself. Instead of just bending the metal back to form sharp

Customers don't ask for much. All they want is the right product at the right price, delivered on time and free from defects. That doesn't seem unreasonable, but many manufacturers struggle to hit all four points simultaneously. Hitting all four on a consistent basis is harder still. Aggravating, isn’t it? Below we'll give seven examples of how your roll forming manufacturer can improve on-time delivery and packaging.  Don’t let your manufacturer overlook these important processes as it processes your order. Take it from the guys with a 99.16% on-time delivery rate. 7 ON-TIME DELIVERY/PACKAGING ISSUES, & WAYS YOUR ROLL FORMING MANUFACTURER CAN FIX THEM Few metal roll forming companies set out to be late. Delays happen when things don't go according to plan. Packaging and delivery is a sore spot for many OEMs dependent on a big batch of components. For some reason, this bottleneck has gone unaddressed for far too long. Here are seven issues (and solutions) we’ve pers

While it's certainly niche, roll forming is still like any other metal manufacturing process. A little collaborative engineering and a lot of lean manufacturing practices equal mutual success. Your roll forming manufacturer should involve its engineers at the very onset of your component design. This ensures your parts come out in the most efficient and economical way. This is just a taste of the full-service experience you deserve and should expect from a metal roll forming company: WHAT IS A TRUE FULL-SERVICE ROLL FORMING MANUFACTURER? To work with a single-source supplier is to enjoy the benefits of collaborative engineering: Receive expert advice on choosing the optimal material for your application Eliminate expensive, time-consuming secondary operations by identifying opportunities to punch holes, notches, or tabs in-line with roll forming tools Improve your original part design to work flawlessly with the other components in your system Once a program is up and running, ther

Just roll forming isn’t very valuable to you. You can do just roll forming in-house. To be competitive, a manufacturer has to offer value throughout your supply chain, from beginning to end of the project. A roll forming manufacturer has experience in optimizing designs, processes, and post-production operations for lowest costs and lead times. This is the primary advantage to outsourcing roll forming. You just have to know what to ask for. Here’s how roll forming services can cut your costs and lead times: OEM ROLL FORMING SERVICES DONE RIGHT IN 6 STEPS You can get more out of your roll forming services by: Working with your manufacturer to optimize your part design for the roll forming process Making sure your manufacturer has a proper understanding of the application Outlining custom packaging needs at the start Understanding your manufacturer's supply system procedures Making sure your manufacturer understands raw material management and market activity Taking advantage of vend

What does an OEM roll former do? Is the process any different from architectural roll forming? And how is either going to solve your project’s case? We’ll clue you in (since we do both). A roll forming company can offer parts you can use for your own brand-name product and metal trim moulding produced under its own line. So ask a potential vendor about its capabilities -- you may be surprised at the versatility of metal bending services. OEM METAL BENDING SERVICES SINCE 1904 Why it’s called “OEM” -- original equipment manufacturer --  is a mystery. An OEM supply company is actually one that makes products out of components manufactured by another company. That second company then sells the assembled, finished product to users under its own brand name. So what does a custom roll forming company do for OEM buyers? 1. Accurate Tolerances An OEM part is more about function, so tolerance and precision are especially important. Your roll former should stick as closely as possible to the agre

Quick: Which charges higher prices for metal fabrication -- a company that has in-house roll forming tooling design capabilities or one that outsources it? Perhaps a follow-up question should be, “Which fabricator will save the most time and do a better job?” This isn’t to say that the price of roll form tooling doesn’t matter. For roll formers and those who use their services, whether to keep tool making in-house or outsource it is a business decision. Yet there’s no simple answer -- you’ll have to account for several variables to figure out which is more cost-effective. Hopefully the following will help you come up with the right solution: PLUSES AND MINUSES OF ROLL FORMING TOOLING DESIGN IN-HOUSE VS. OUTSOURCING Businesses of all kinds face the in-house/outsource dilemma from time to time, and there are some things the decision-making processes have in common: Risks Outsourcing: The chance always exists that the roll form tooling supplier won’t live up to its advertised capabilities

Most contractors have seen and done it all. But when it comes to installing trim moulding, one material that they may have limited experience with is metal. Wood, vinyl, and MDF are the most common materials for trim. If you're working on a project that calls for metal moulding installation, don't be intimidated! Just be sure you know what it takes to achieve a successful installation, and put the right professionals in place to accomplish it.  This post will take a closer look at what architects and designers expect from you or your installer when they specify metal commercial moulding: (Related Post: If you’re on the designer/architect side of the situation, you might also want to read this.) UNDERSTAND WHY YOU’RE INSTALLING DECORATIVE METAL TRIM MOULDING First and foremost, any contractor should understand the decision criteria used by the designer or architect to ensure they order the correct type of moulding, often ID’ed by a moulding profile number. Secondly, it's imp

Roll forming is one of the most efficient and cost-effective methods of shaping metals. However, it isn’t free. So what major factors affect the cost of roll forming? (Hint: Your design choices play a big part in it.) ROLL FORMING COSTS -- WHAT GIVES? Think of metal forming costs in three ways: Setup Time -- Refers to the amount of time it takes to insert and remove the roll tools from the machine. Run Speed -- Represents the speed at which you can feed metal through the machine. Materials -- Refers to the raw materials needed for the project. Here is a closer look at each factor along with an explanation of how they affect roll forming costs. Understanding these three aspects will enable you to make the most cost-effective decision. Setup Time Setup time refers to the amount of time it takes to put the roll tools into the machine and then take them out. This time will vary based on the complexity of the shapes you’re producing, which relates directly to the number of steps required fo