From Concept to Production: Custom Rollform Solutions
Design consultation, tooling, prototyping, and high-volume production under one roof.
> Download Custom Solutions GuideYour End-to-End Rollforming Partner
When it comes to complex manufacturing, you need more than just a vendor; you need a dedicated partner. At RPM, our comprehensive custom rollforming services seamlessly guide your project from initial design consultation and engineering straight through to final quality assurance and reliable delivery. By managing every stage of the process under one roof, we eliminate supply chain bottlenecks, control costs, and guarantee precision-engineered profiles tailored to your exact specifications. Partner with RPM for a streamlined, single-source custom rollforming solution that brings your vision to life from start to finish.
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
Maximize production efficiency and eliminate costly secondary operations with RPM’s advanced in-line pre-punching capabilities. Across our 17 high-performance manufacturing lines, we integrate high-speed punching directly into the custom rollforming process. This allows us to pierce precise hole patterns, slots, and notches into the flat metal strip before it ever enters the forming rolls. By combining punching and shaping into a single, continuous operation, we deliver complex, ready-to-assemble profiles with absolute dimensional consistency, saving you time, reducing material handling, and lowering overall fabrication costs.
Rigorous Quality Management & Industry Certifications
At RPM, quality isn’t just a final inspection step; it is built into every phase of our manufacturing process. As an ISO 9001:2015 registered company, we operate under a proven Quality Management System (QMS) that drives continuous improvement and guarantees absolute precision for every profile we manufacture.
Our commitment to excellence is backed by top-tier industry credentials, including CWB, AWS, and ASME Section IX welding certifications, ensuring that every structural member we produce meets rigorous safety and performance standards. When you choose RPM for custom rollforming, you are partnering with a team dedicated to delivering high-performance, compliant components that consistently exceed your expectations.
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.