Metal Roll Forming

Metal Roll Forming is a metal fabrication technique for processing sheet metal through a series of rollers that bend the metal into the profile desired. The process, while simplistic in design, can provide an extensive range of geometric possibilities for products that have a consistent cross-section along their length.

Roll Formed metal pieces are generally lighter weight than similar pieces that are formed by extrusion or other metal fabrication processes. Due to the metal being work hardened in a cold state, it is possible to achieve thin walls that offer consistent strength and durability. The roll forming process is energy efficient and can streamline manufacturing operations with its capacity to process materials that are pre-finished or even painted.


Metal Roll Forming Companies

Johnson Brothers Metal Forming creates roll formed metal products for a broad range of applications. They provide the entire roll forming process in-house, from conception and fabrication to finishing. Johnson Brothers is based in Chicago, but can provide service throughout the Upper Midwest and Canada.


Metal Roll Forming Processes

Roll forming sheet metal is an ideal process for the creation of parts that have a consistent profile and need to be produced in long lengths at a relatively high speed of production. Many inline press fabrication processes for roll forming are automated and can be designed and programmed for pre-fabrication and post-fabrication options such as punching, cutting, and notching.

This video by Johnson Brothers Metal Forming demonstrates the metal roll forming process for a variety of profiles and products.


The accuracy and speed of roll forming makes it a cost effective option for the production of components for many manufacturers. The option of using pre-finished materials makes roll forming an affordable choice for many applications by limiting the additional expense associated with secondary finishes. Pre-finishing options that are frequently offered for roll forming materials include:

  • Painting
  • Anodizing
  • Plating
  • Polishing
  • Galvanizing
  • Perforating
  • Laminating
  • Embossing

Roll Forming Applications

The roll forming process can be used to create a number of profiles including:

  • Metal Channels: U-Channel, J-Channel, C-Channel, Box Channel, Hat Channel, Strut Channel, and Z-Channel
  • Tubing: Rectangular & Square Open Seam Tubing, Lock Seam Tubing, Open Seam Tubing, Split Seam Tubing

Products that are created using roll forming include, but are not limited to

channels, profiles, mouldings, trim, edging, tracks, slates, strips, brackets, framing, railings, flanges, cable trays, shrouds, poles, rings, bands, and struts.

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