OEM Metal Roll Forming Machine

 

Overview

 

An OEM metal roll forming machine is a versatile industrial equipment system used to efficiently mass produce long lengths of precision custom metal parts and profiles for original equipment manufacturers.

 

The continuous roll forming process shapes metal coil feedstock into various rails, frames, enclosures and structural components using a series of rotating roller dies.

 

This guide provides a comprehensive overview of OEM roll former technology, including:

 

• Machine types and components
• How the roll forming process works
• Design considerations
• End use applications
• Material and specification standards
• Cost analysis
• Comparisons with other metal fabrication methods

 

Gaining insight into OEM metal roll former capabilities assists manufacturers evaluating optimized production solutions for metal components used in specialized equipment and products.

 

 

Types Of OEM Metal Roll Forming Machines

 

There are two primary machine configurations for high volume OEM parts production:

 

Fixed Head Roll Formers

 

• Typically 10-16 forming stations
• Common base profiles
• Lower tooling cost
• Repeat jobs

 

Quick Change Roll Formers

 

• Individual stations per head
• Flexible tooling for profile variations
• Higher output variety
• Frequent form changes

 

Main Components Of A Metal Roll Former

 

A typical OEM metal roll forming system integrates these main sections:

 

Coil Payoff Reel

 

• Holds raw coil at unwind station
• Feeds strip through process

 

Entry Guides

 

• Align and straighten strip
• Optimize material feed

 

Accumulator/Bridle

 

• Creates back tension zone
• Smooths flow variations

 

Forming Stations

 

• Progressive die rollers shape material
• Number & type determine profile

 

Cutter

 

• Shears finished parts to length
• Pneumatic, servo electric

 

Exit Conveyor

 

• Transfers finished product
• Links to secondary operations

 

Automation Controls

 

• HMI and PLC hardware
• Touchscreen programming
• Data feedback

 

How Metal Roll Forming Machines Work

 

The OEM roll forming process shapes metal coil feedstock into rails, frames and custom profiles by bending and forming the strip material incrementally as it passes through a series of roller die stations:

 

1. Powered coil payoff reel feeds raw coiled strip into initial machine guides

2. Entry guides align strip and feed into first roller station

3. At each station, machined rollers make precision bends and forms

4. Strip exits slightly more formed moving to subsequent stations

5. Finished custom profile emerges at end of forming line

6. Profile cutoff to length by pneumatic or servo shear

7. Formed parts conveyed for additional fabrication

 

The number of roller die stations determines possible shape complexity. Quick changeovers accommodate low to high mix production.

 

 

Key Design Factors For OEM Roll Forming

 

Equipment specifiers evaluate numerous characteristics when selecting OEM metal roll formers:

 

Product Type

 

• Metal structural framing
• Equipment enclosures
• Machine bases and supports

 

Material

 

• Mild steel
• Stainless steel
• Aluminum
• Other alloys

 

Thickness

 

• 20 gauge to 1/4”
• 0.6 mm to 6 mm

 

Profile

 

• C & U channels
• Complex rails and frames
• Hollow box sections

 

Length

 

• Up to 30′ possible
• Exit tables for support

 

Speed

 

• 10 to 100+ feet/min
• Low vs high cycle times

 

Changeover

 

• Quick change tooling
• Repeatable accuracy

 

Automation

 

• Level required
• Data feedback

 

Floor Space

 

• Line length
• Layout constraints

 

Standards For OEM Roll Formed Metals

 

While having fewer universal specifications, these guidelines apply to certain OEM components:

 

Standard	Description
ASTM A792	Steel sheet UV performance
ASTM A1008	Low carbon steel sheet grades
EN 10346	Continuously hot dipped coatings
IATF 16949	Automotive quality management

 

Typical Applications For Roll Formed Metals

 

Common end uses for roll formed metals in original equipment include:

 

Electrical Equipment

 

• Motor and transformer frames
• Switchgear housings
• Generator enclosures

 

Machinery Structures

 

• Machine bases
• Robotic arm supports
• Conveyor frames

 

Commercial Appliances

 

• Refrigerator liners
• Range and oven cavities
• Washer and dryer drums

 

HVAC Components

 

• Furnace and AC housing
• Heat exchangers
• Ducting frames

 

Furniture

 

• Desk and cabinet frames
• Shelving posts and rails
• Table bases

 

White Goods

 

• Dishwasher tubs
• Clothes dryer cylinders
• Range oven cavity frames

 

Specifications

 

Metric	Typical Range
Thickness	0.5 mm – 3 mm
Width	10 mm – 300 mm
Height	10 mm – 150 mm
Length	50 mm – 20,000 mm
Holes	1 mm – 20 mm dia
Loads	50 kg – 3000 kg

 

Manufacturers Of Oem Metal Roll Forming Machine

 

Leading global OEM metal roll former manufacturers include:

 

Company	Location
Formtek	USA
Bradbury	USA
DIMA	Italy
Shanghai Winsun	China
BOTOU Xianfa	China

Pricing

Machine	Average Cost (USD)
Basic Manual Roll Former	$38,000
20 Station Servo-Electric	$120,000
High Speed Quick Change	$240,000

Rolled Part	Typical Cost per Kg (USD)
Mild Steel Channel	$2
Stainless C-Rail	$5
Aluminum Profile	$10

 

Advantages Of OEM Metal Roll Forming

 

Benefits

 

• High hourly production rates
• Precision tolerances
• Low operational costs
• Minimal secondary fabricating
• High material utilization
• Lean, continuous-flow process

 

Limitations

 

• Substantial initial capital costs
• Mostly long, straight geometries
• Tooling expensive for low volumes
• Can require secondary punching, welding, drilling

 

 

FAQ

 

What metals work with OEM roll forming?

 

All ductile metals can use roll forming including low carbon steel, stainless steel, aluminum, copper, and titanium alloys. Hardened materials may require specialized tooling.

 

What tolerances are possible with OEM roll formed parts?

 

Roll formed components can reliably achieve profile tolerances between +/- 0.1 mm to +/- 0.25 mm for quality machines depending on the material gauge.

 

How long can an OEM roll formed metal part be?

 

Standard maximums with support tables are around 18 meters (60 feet). Custom long bed machines can produce sections over 30 meters (100 feet).

How thick of metal can an OEM roll former handle?

 

Thicknesses from 0.15 mm (30 gauge) to about 6 mm (1/4 inch) are typical for an average OEM roll former. Beyond that may require custom heavy-duty equipment.

 

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