Benefits and Advantage of Roll Forming

1. Efficiency
The speed of roll forming is due to the long coils of metal it uses that are rapidly fed into the forming machine. Since the machine is self-feeding, there is little need for human monitoring, which lowers the cost of labor. Punching and notching during pre-feeding avoids the need for secondary operations.

2. Cost savings
Metals do not need to be heated for roll forming, which significantly lowers energy costs. The careful control and lubrication of moving parts reduces tool wear and the cost of component replacement. The smooth finishes of completed parts removes the need for secondary processes such as deburring or trimming of flash. Parts are produced in large quantities reducing the cost of the final product.

3. Flexibility
Complex and intricate cross sections can easily be produced using ferrous and non-ferrous metals. In some processes, it is not possible to shape a metal that has been painted, plated, or coated. Roll forming can easily shape them regardless of the type of finish.

4. Quality
Products are more uniform and consistent across a complete run. Tolerances are very tight with extremely precise dimensions. Sharp, clean contours are maintained with the absence of die marks or deformities.

5. Roll Formed Parts/Length of parts
Since the metal is fed into the machine, any length can be produced using the same tooling for any part.

6. Less scrap
Roll forming produces one to three percent scrap for each production run, which is far less than any other metal working process. The lower amount of scrap lowers the cost of working with expensive metals.

7. Repeatability
A major problem with bending metal is residual stress, which negatively affects repeatability. The rapid processing of roll forming helps metals retain their residual stress as well as any loss of weld seam control.