Custom Roll Forming from Concept to Production
Roll Forming Services from Design and Tooling to High-Volume Production.
Download Custom Profile GuideYour End-to-End Roll Forming Partner
Complex manufacturing calls for more than just a vendor. RPM's custom roll forming services take your project from design consultation and engineering through tooling, prototyping, production, and quality assurance. Managing each stage under one roof reduces supply chain risks and delays, controls costs, and keeps profiles consistent with your specifications.
Design Consultation
Every custom roll forming project starts with a review of your profile design, application requirements, material specifications, and production volumes. If you only have a concept, a sketch, an existing component, or a problem to solve, our engineering team can start from there.
Profile Engineering
Our engineers refine your roll formed profile for manufacturability before any tooling is built. Involving RPM early in the design process often helps improve manufacturability, reduce costs, and shorten development timelines.
Tooling Development
Roll form tooling is designed and maintained in-house, based on your approved profile and material. Tooling ownership is determined at the start of each project and outlined clearly in your quote.
Prototyping and Samples
New tooling is tested and validated through sample production runs. This lets you review and approve the profile before full-scale roll forming production begins.
Production
Production runs across 17 roll form lines in two plants, at line speeds up to 100 ft/min. Profiles range from 6 inches to 40 feet in length and from 0.008" to 0.187" in thickness, in steel, aluminum, brass, zinc, and copper.
In-Line Secondary Operations
Pre-punching, notching, embossing, cut-to-length, and in-line laser welding can be built directly into the roll forming line. Combining these steps can reduce handling and production costs, so components arrive ready for assembly.
QA and Delivery
Every profile is produced under an ISO 9001:2015 registered Quality Management System, backed by CWB, AWS, and ASME Section IX welding certifications. Our team works with you to coordinate delivery around your project schedule.
Capacity
- 2 Plant Locations
- 17 Rollform Lines
- 100,000+ sq ft of production space
- Line speeds up to 100 ft/min
- Annual capacity: 60,000+ tons of steel
- In-house tooling design & maintenance
Specifications
Length:
- Minimum: 6”
- Maximum: 40 feet or longer if required.
- Roll forming does not have length limitations
Thickness:
- Minimum: 0.008”
- Maximum: 0.187” (Future Expansion: 0.250”)
Material
- Steel (CRS, Galv, HRPO, Galvalume, and Stainless)
- Aluminum (Mill, Painted, and Anodized)
- Brass
- Zinc
- Copper
Capabilities & Secondary Operations
RPM's value extends beyond roll forming. Through integrated pre-punching, stamping, and in-line laser welding capabilities, we help customers consolidate manufacturing processes, reduce costs, and improve overall product quality. By incorporating secondary operations directly into production, we deliver components that arrive ready for assembly while maintaining the precision and consistency our customers expect.
In-Line Pre-Punching & Custom Hole Patterns
RPM's in-line pre-punching adds hole patterns, slots, and notches to the flat strip before it enters the forming rolls. Available across our 17 roll form lines, combining punching and forming in one continuous operation produces ready-to-assemble profiles with consistent dimensions, while reducing material handling and secondary processing.
Rigorous Quality Management & Industry Certifications
RPM builds quality into every stage of production. As an ISO 9001:2015-registered company, we operate under a Quality Management System focused on continuous improvement. Our welding work is backed by CWB, AWS, and ASME Section IX certifications, ensuring structural components meet your project's standards.
Frequently Asked Questions
What does the rollform tooling development process look like, and who owns the tooling?
The tooling development process begins with a review of your profile design, application requirements, material specifications, and production volumes. Our engineering team works closely with you to optimize the design for manufacturability before tooling is designed and produced. Once completed, tooling is tested and validated through sample production runs prior to full-scale manufacturing.
Tooling ownership is determined at the start of each project and is outlined clearly during the quotation process. We work with customers to establish an arrangement that best supports their long-term production requirements.
What are your typical lead times from initial design to first production run?
Lead times vary depending on profile complexity, tooling requirements, material availability, and project scope. For new custom profiles, projects typically progress through design review, tooling development, sampling, and production approval before the first production run.
Our team provides estimated timelines during the quoting process and works closely with customers to meet project schedules whenever possible.
Do you offer design and engineering support if we only have a concept or a problem to solve, not a finished profile
Absolutely. Many projects begin with an application challenge rather than a completed design. Our engineering team can work from concepts, sketches, existing components, or performance requirements to develop a custom roll-formed solution that meets your needs.
By involving RPM early in the design process, customers often benefit from improved manufacturability, reduced costs, and shorter development timelines.
What are your minimum order quantities, and at what volumes does rollforming become more cost-effective than press braking or extrusion?
Minimum order quantities vary depending on profile complexity, material requirements, and tooling considerations.
Roll forming generally becomes more cost-effective when consistent volumes, longer production runs, or repeat demand are involved. Compared to press braking, roll forming offers greater efficiency, consistency, and production speed for medium- to high-volume applications. Compared to extrusion, roll forming can often provide a more economical solution for many steel and aluminum profiles while maintaining excellent structural performance.
Our team can review your application and production requirements to determine the most cost-effective manufacturing approach.
Can secondary operations like punching, notching, and cut-to-length be done inline, or are they separate processes?
Yes. Many secondary operations can be integrated directly into the roll forming process, including punching, notching, embossing, cut-to-length, and select welding applications.
Incorporating these operations inline can reduce handling, improve efficiency, and lower overall production costs. Our engineering team will review your requirements and recommend the most effective manufacturing method for your application.