Roll formed Tubes Case Study

Situation

A European-based company needed roll formed tubes used in seat bottoms from a supplier located near their Canadian operations.

Challenge

The tube is made from Advanced High Strength Steel (AHSS) and requires more than 20 passes on the roll form line to be bent into a tube shape. Three laser welds are also needed along the full length of the part to create one continuous seam.

Solution

The Diversified Business Unit, which supplies many industries, including automotive, healthcare, agricultural, recreational and office furniture, took on the challenge of supplying the tube. The sheet of steel starts out pre-punched on the side that becomes the tube’s exterior. The steel is then flipped before it goes through the roll form line, ensuring that once it is rolled into a tube, steel protruding from the punch process is on the tube’s interior. After being incrementally bent while moving through over 20 mandrels, Shape’s first in-line laser weld places three welds over the full length of the part. It then goes into a double-bladed saw, designed and built by Shape engineers, that cuts the piece into two finished parts with tight tolerances.

Result

The customer receives a consistently high-quality product, despite a challenging production process, in a location close to their facilities.