Roll forming is a continuous manufacturing process in which a metal coil or strip is guided step by step through a series of forming rolls. This produces precise metal profiles with a constant cross-section. Thanks to its high production speed, minimal material waste, and excellent dimensional stability, roll forming is the go-to production method for large series of profiles in industries such as construction, automotive, and manufacturing.

What is Roll Forming?

Roll forming (also known as profile rolling, profile rolling, sheet metal forming, shaping rolling, cold roll forming, or roll bending ) is a continuous forming process in which flat metal sheets or long strips (usually coiled steel strip; coils) are gradually formed into complex profiles using a series of rolls.

The steel strip is fed through several rolling stations, each of which applies a small amount of deformation until the desired profile is achieved. Because the amount of deformation per rolling station is limited, several consecutive rolling stations are needed to gradually shape the material into the correct form.

Roll forming is sometimes incorrectly referred to as “cold rolling.” Cold rolling, however, is a different process in which the thickness of the steel is reduced by rolling. In roll forming, the material thickness remains virtually the same; only the shape of the material changes.

The Roll Forming Process, Step by Step

The roll forming process is custom work and involves several precisely executed steps to achieve the desired result. First, the metal sheet is fed into the roll forming machine, after which a series of rolls, each with a specific shape, guide the sheet. These rolls gradually bend and shape the metal into the desired form. The process ends with cutting the formed metal to the correct length.

Flower Pattern

The rolls are carefully manufactured using a so-called flower pattern, which ensures the sequential changes to the metal sheet. The shape of each roll is determined based on the individual parts of the flower pattern. The roll contours are then derived from the flower pattern profiles. Each color in the flower pattern below illustrates one of the sequential bends used to complete the profile. Each color represents a single bending operation.

Roll forming is ideal for producing parts with a consistent profile in long lengths and in large quantities. During the roll forming process, various operations can be performed, such as punching, shearing, etc.

This process is often used to produce metal profiles for applications in construction, the automotive industry, horticulture, the furniture industry, and more. Understanding roll forming requires knowledge of machining and the physical properties of metals.

Roll Forming Machine, or Roll Forming Line

A roll forming machine is the basic machine used to produce a profile. The machine consists of a series of roll forming stations arranged one after the other, each of which consists of an upper and lower shaft with various profile rolls.

A roll forming line can consist of several parts, e.g.:

Unwinding reel (decoiler) with coil carriage
Straightener
Punching installation
Roll Forming Machine
Cut-off installation
Stacker

1. Decoiler

A coil or strip material is placed on the core of the reel. The core of the Decoiler can adjust in diameter so that it clamps the coil, keeping it securely in place on the mandrel.

2. Straightener

Before the material is punched, it must first be flattened so that it does not get jammed in the tooling. These come in various types. From a single roller to more than 21 leveling rollers. We refer to precision levelers as “levelers.” These may or may not have support rollers to keep the leveling rollers straight.

3. Punching installation

A punching machine consists of a single punch or a combination of different, interchangeable punches. It is also possible to incorporate a servo-driven punching machine into the production line.

4. Roll Forming Machine

The roll forming machine consists of several stations equipped with profile rolls. These can be swapped out for a different profile or mounted on a so-called changeover cassette. This allows for quick changeover times when multiple profiles are produced on the same line.

5. Cut-off installation

When working not with separate sheets, but from coil, the profile should be shortened at the end of the roll forming line:

– Using hydraulic shears
– Using a cut-off saw.

The choice depends in part on the complexity of the profile. Depending on whether it is a continuous or a start/stop roll forming process, it can also be possible to cut to length in-line (we call this a flying shear).

6. Stacker

After cutting, the machine stacks them as desired by the user.

Applications of Roll Forming

Roll forming is widely used in various industries because of its versatility and efficiency. Some common applications include:

Construction industry: For the production of roof panels, roof cladding, wall cladding, structural profiles and structural elements.
Greenhouse Construction: For the production of growing troughs in greenhouses.
Automotive industry: For the production of body parts, such as door and window frames.
Industrial applications: For the production of frames, pipes, and other structural components.

Advantages of Roll Forming

Roll forming offers several advantages over other manufacturing methods, including:

High production speed: You can run the process continuously, which ensures fast production.
Accuracy: The rollers ensure that the shape of the final product remains consistent and accurate.
Material savings: Roll forming minimizes waste, which saves you money and improves sustainability through efficient use of metal.

Roll Forming: An Indispensable Link in the Production Chain

All in all, roll forming has become an essential part of the modern manufacturing industry. It offers an efficient and cost-effective way to produce complex metal profiles for a wide range of applications. Given its versatility and advantages, roll forming is expected to remain an integral part of the global manufacturing chain.

When should you choose roll forming?

Roll forming is the ideal manufacturing technique when:

large numbers of identical profiles are required;
consistent product quality is important;
long profiles need to be produced;
low unit production costs are desired;
a small amount of material loss is acceptable;
Multiple operations must take place on a single Production line.

Compared to edging or welding, roll forming is particularly advantageous for medium- to large-volume production runs.

Which materials can be roll-formed?

Virtually all malleable metals can be roll-formed, including:

galvanized steel
cold-rolled steel
hot-rolled steel
high-grade structural steel
Stainless Steel
aluminum
copper
pre-painted steel
Magnelis®

Which profiles can be roll-formed?

Examples of roll-formed profiles

A roll forming line can be used to produce the following profiles, among others:

C-profiles
Z-profiles
U-profiles
Sigma Profiles
Hat Profiles
Omega profiles
Gutters
Roofing profiles
Cladding profiles
Solar Profiles
Cable Trough Profiles
Trapezoidal profiles
Standing Figures
Rails
Door Profiles

See also here for an overview with images.

Roll Forming vs. Bending

Roll Forms	Edges
Continuous production	One product at a time
Large series	Small series
Low cost per product	Higher cost price
Long profiles	Shorter sections
Fully automatic	More actions

Be sure to check out these folding machines, too.

Roll Forming vs. Pressing

Whereas a press performs a single operation, a Roll forming line gradually forms the profile over multiple roll stations. This results in less stress in the material and allows even complex profiles to be produced with high precision.

FAQ:

Frequently Asked Questions About Molding

What is the difference between roll forming and profile rolling?

In practice, the two terms usually refer to the same process. Both terms describe the gradual shaping of a metal strip into a profile using a series of rolling stations.

Starting with which series does roll forming become interesting?

Due to the investment required for the tooling, roll forming is particularly suitable for medium and large production runs.

Which materials can be roll-formed?

Steel, stainless steel, aluminum, copper, and many other metals.

How fast does a roll forming line operate?

Depending on the profile, the speed varies from a few meters to tens of meters per minute.

Pasterkamp Metal Sheet Solutions: More Than 20 Years of Experience

Pasterkamp Metal Sheet Solutions has been supplying complete roll forming lines for a wide range of applications for more than twenty years. Together with our international partners, we develop Custom solutions for, among other things:

roof and facade systems;
steel window frame profiles;
cable support systems;
solar panel profiles;
warehouse shelving;
greenhouse gutters;
structural profiles.

Our engineers oversee the entire process: from profile design and flower pattern to production, installation, and service.

Any advice on rollforming needed?

Would you like to know if roll forming is suitable for your product or production process? Our specialists would be happy to advise you on the options. Together, we’ll determine which profile, Roll forming line, and Automation best meet your needs.

Feel free to contact us for a consultation or a customized quote.