Is Custom Roll Forming the best solution for your business?
From your idea, we can design, manufacture, finish, package, palletize, and ship your custom parts, on time and on budget. Roll forming is not right for every application, but it does have some distinct advantageous over casting, machining, etc.
With more than 35 roll formers and related metal forming equipment, MP Metal Products has the capability to roll form a wide range of profiles. We process metal strip, coil and sheet in gage thickness from 0.005" up to 0.165", and widths up to 48" depending on the shape. MP Metal Products specializes in private-label manufacturing typically for OEM accounts expecting quality parts delivered on time.
MP Metals has curated a selection of informative articles and websites to help you learn more about the roll forming process in general. Please browse our selected library:
Roll Forming
Roll forming, also spelled roll-forming or rollforming, is a type of rolling involving the continuous bending of a long strip of sheet metal (typically coiled steel) into a desired cross-section.
Roll Forming: Discovering its Various Benefits
This is the most complete description of roll forming on the internet.
Metal Channel: Types, Uses and Metals Used
Here is the most comprehensive information about metal channels on the internet.
Metal Moulding: Applications and Types
This article will take an in-depth look at metal moulding, interchangeably known as metal Moulding.
Steel Channels: Types, Applications and Advantages
This article will take an in-depth look at steel channels.
Is roll forming an option?
The basics behind justifying one of the oldest and still misunderstood metal forming processes.
Continuous improvement for roll forming - Part I
The basics behind justifying one of the oldest and still misunderstood metal forming processes.
Continuous improvement for roll forming - Part II
Analyzing problems, maximizing output.
New possibilities in roll forming
A tried and true method of metal forming continues to evolve.Volume
How much do I need annually?
Typically, a new shape should have about 50,000 lineal feet to justify a tooling investment. If a shape already has tools, the minimum economical production may be closer to 5,000 lineal feet, depending on minimum metal purchases.
Material
Is the desired metal available in coil or sheet?
While a variety of aluminum and steels can be roll formed, it is important to evaluate the forming characteristics of the desired material to confirm suitability for the desired shape.
MP Metal Products processes Carbon Steels in most coatings, Stainless Types 200, 300 and 400 series, Aluminum Mill Finished and Pre-Coated, Brass, Copper and Bronze.
Roll forming strategies for high-strength material
Modern technology addresses material challenges for metal fab shops.
Selecting the right materials for roll forming—Part 2
How mechanical properties affect production.Tooling
As a coil-based process, typical minimum production runs are around 5,000 lineal feet if tooling is available. Larger quantities are more economical. If tooling has to be made we have found that at least 50,000 lineal feet annually helps to justify the investment.
Lengths are quite flexible when a part is made from coil.
However different heights and widths are a different story. Changing the width may be possible and require that roll tooling be split in places. Changing height is usually not feasible.
Understanding metal roll forming and its tooling
Breaking down the roll forming process by studying each place the metal is changed.Tolerances
Let’s start with identifying what tolerances you need to reach the Fit, Form and Function of the profile. Outside tolerances are fairly straightforward to maintain and material “spring-back” can be addressed by purposely overbending where possible. Consider too that inside tolerances are less controllable because as the material thickness increases or decreases, the change in thickness moves to the inside.
Please look at the Design Suggestions for typical tolerances.
Or send us a print to discuss the issues with you.
Cosmetics / Aesthetics
What surface is visually important? It helps to identify cosmetic areas at the beginning of the project. Normal production can introduce pressure marks and forming lines. Operators can be alerted to watch for things like surface blemishes, paint chipping, scuffing, crazing, galvanize fracturing and the like.
Feel free to send a print with important cosmetic areas identified. That will help guide appropriate packaging, too.
Holes
If the part you want has holes, slots or notches, we ask that you send a print for us to examine. Holes that are punched too close to an end or radius usually distort. Sometimes there are opportunities to punch details in flat coil before roll-forming. At other times it may make more sense to punch the holes later in the process. Depending on the accuracy of the opening needed, there are methods to control the process and location. A few of the options may include mechanical pick-ups, rotary encoders, flag switches or paddles.
Packaging
Please let us know how existing parts are packaged. It is helpful to be aware of size and weight constraints.
If the parts are new let’s discuss what packaging will work best for you.
Common containers are corrugated boxes, plastic re-useable crates, flat wooden skids, gaylord boxes on skids, wooden boxes, and the like. Heavy, dense or long parts may require custom skids or crates.
Shipping
MP Metal Products is centrally located in the Midwest, in a small community named Ixonia, Wisconsin. We are between Madison and Milwaukee, about 2 hours north of Chicago.
We ship both full truckloads and LTL (less-than-truckload) of customer merchandise. Most of the traffic is east of the Rocky Mountains, but some shipments spread out around the country with a few going overseas. Typically our customers take advantage of contracts to make their own freight arrangements.
Lighting bezel with a bolt hole for tightening. - MP Metals
Custom channels strapped and ready for shipping. - MP Metals
Custom channels ready for packaging. - MP Metals
Wood grain embossed and painted sheet - MP Metals
Lance punches - MP Metals
Stamping - MP Metals
Packaged bundles - MP Metals
Post punch - MP Metals
Post punch lance - MP Metals
Tote packaging - MP Metals
Press broken "V" - MP Metals
Printed plastic cladding - MP Metals
Production space, Ixonia, Wisconsin - MP Metals
Punched holes - MP Metals
TIG welded tube - MP Metals
Roll formed angle - MP Metals
Roll forming machine - MP Metals
Roll formed channel - MP Metals
Roll tool rack - MP Metals
Stacked angles ready for packaging - MP Metals
Staged shipments - MP Metals
Stamped trays - MP Metals
Roll formed metal parts are usually cheaper to manufacture than cast or machined parts.
Contact MP Metals today and let us answer your questions about roll forming and maybe we can save your company some money, too.