Roll forming is a procedure where continuous bending operations are applied to sheet metal or strips of metal to plastically deform the metal along a linear axis. Roll stations shape the metal in tandem sets of rolls through progressive stages until the required configuration is achieved.
Virtually any material that can be formed through sheet forming techniques can also be roll formed. It is ideal for large quantities of parts with long lengths. Multiple lengths of parts can be produced from the same set of tooling.
The process is extremely cost effective for large production runs. When dimensional consistency is important, roll forming is an excellent solution. The diagram below shows a typical set-up for roll forming.