Roll forming services

Our ability to develop several unique roll forming, welding, injection molding and assembly processes has made us the leading innovator in our field. Our developments include inline sweeping technology and bending high-strength steel.

Shape specializes in high-volume, continuous feed roll forming of various materials, including ultra high-strength steel and aluminum. Metal roll forming is a complex process, one that provides economic advantages over other metal forming processes. The roll form process begins with a coil of steel, aluminum or other material. The material is unrolled into a primary die, which can pierce a specified hole pattern into the flat sheet. The material then enters the rolling mill where it is progressively roll formed into a desired shape as it passes through a series of customized rolls.

A roll formed part can be enhanced by additional piercing, welds and/or bends. Welding can be accomplished in-line. Parts that require a curve go through a sweep process before being cut to length. These in-line rollforming processes allow Shape to provide customers with a quality product at a better value because of decreased part handling. Many of our customers utilize the same roll form tooling on multiple components, which allows for millions of dollars in roll form tooling cost savings.

• Specializing in Advanced High Strength Steel (AHSS) roll forming
• Patented roll formed cross sections to optimize energy absorption & structural integrity
• Capable of roll forming 0.7-8mm gage parts
• Up to 220ksi (1500MPa) in Ultimate Tensile Strength (UTS)
• In-line processing capabilities to eliminate secondary operations
• Roll form variable and constant sweeps
• Welding, trimming, forming & piercing