Overview
A door frame roll forming machine is specialized equipment designed for manufacturing steel door frames with high precision and efficiency. These machines are widely used in the construction and interior industries, enabling the production of standard and custom door frames for residential, commercial, and industrial buildings.
Key Features
✅ Fully automatic operation – PLC-controlled for high-precision production.
✅ Customizable profiles – Supports different door frame designs and sizes.
✅ High-speed production – Capable of producing 10-30 meters per minute.
✅ Durable construction – Uses hardened tool steel rollers for longevity.
✅ Hydraulic punching & cutting – Ensures precise hole placement and clean cuts.
In this guide, we’ll cover:
✅ Types of door frame roll forming machines
✅ How the roll forming process works
✅ Best materials for door frames
✅ Cost analysis & pricing guide
✅ Top manufacturers & why Sunway Machine is a trusted choice
Let’s get started!
Types
Different door frame roll forming machines are designed for various production needs and levels of automation.
1. Manual Door Frame Roll Forming Machine
- Requires manual adjustments for different frame sizes.
- Suitable for small-scale production.
2. Semi-Automatic Door Frame Roll Forming Machine
- Incorporates a PLC control system for improved accuracy.
- Requires manual profile adjustments but offers faster production.
3. Fully Automatic Door Frame Roll Forming Machine
- Features CNC automation for quick profile adjustments.
- Ideal for high-volume production with minimal downtime.
4. Quick Change Door Frame Roll Forming Machine
- Allows for fast profile switching without manual adjustments.
- Perfect for factories producing multiple door frame designs.
Sunway Machine provides customized door frame roll forming machines with advanced automation features.
How Door Frame Roll Forming Works
The roll forming process for door frames involves gradually shaping a flat metal sheet into a precisely engineered door frame profile.
Step-by-Step Door Frame Roll Forming Process
| Step | Description |
|---|---|
| 1. Decoiling | The metal coil is placed on a decoiler to feed the material. |
| 2. Leveling & Feeding | The sheet is straightened and guided into the forming stations. |
| 3. Punching & Cutting | The hydraulic system performs precise hole punching before forming. |
| 4. Roll Forming | The sheet passes through multiple roller stations, forming the door frame profile. |
| 5. Final Cutting & Output | The formed door frame is cut to the required length and stacked. |
Pro Tip: A fully automated door frame roll forming machine ensures higher accuracy and lower material waste.
Best Materials for Door Frames
Choosing the right material ensures strength, durability, and corrosion resistance.
Comparison of Materials for Door Frames
| Material | Properties | Best For |
|---|---|---|
| Galvanized Steel (GI) | Corrosion-resistant, affordable | Standard residential and commercial doors |
| Cold-Rolled Steel | Smooth finish, precision forming | High-end office and interior doors |
| Stainless Steel | Rust-proof, durable | Heavy-duty industrial doors |
| Aluminum | Lightweight, corrosion-resistant | Modern architectural applications |
Sunway Machine manufactures roll forming machines compatible with all major door frame materials.
Door Frame Roll Forming Machine Price Guide
The cost of a door frame roll forming machine depends on factors like automation level, production speed, and profile range.
Estimated Price Ranges
| Machine Type | Price Range (USD) | Features |
|---|---|---|
| Manual Machine | 10,000–10,000 – 10,000–30,000 | Manual adjustments, low-speed production |
| Semi-Automatic Machine | 30,000–30,000 – 30,000–80,000 | PLC-controlled, requires manual profile adjustments |
| Fully Automatic Machine | 80,000–80,000 – 80,000–150,000 | CNC-controlled, quick profile switching |
| Quick Change Machine | 150,000–150,000 – 150,000–300,000 | High-speed, automatic profile adjustments |
Looking for a custom quotation? Contact Sunway Machine today!
Top Door Frame Roll Forming Machine Manufacturers
Choosing a reliable manufacturer ensures high-quality machines, long-term support, and global service.
Comparison of Leading Door Frame Roll Forming Machine Manufacturers
| Manufacturer | Country | Specialization | Key Features |
|---|---|---|---|
| WUXI SUNWAY MACHINERY CO., LTD | China | Door frame roll forming machines | Custom solutions, high-speed automation, IoT-enabled machines |
| Dreistern GmbH | Germany | High-precision metal forming | CNC-controlled machines, strong R&D |
| Samco Machinery | Canada | Roll forming for construction | Custom engineering, automation |
| Bradbury Group | USA | Heavy-duty roll forming systems | Robust machines, automation-focused |
Verdict: If you’re looking for custom, high-speed, and cost-effective door frame roll forming machines, Sunway Machine is a top choice for global buyers.
Common Problems & Solutions in Door Frame Roll Forming Machines
Even with high-quality door frame roll forming machines, operational challenges such as roller misalignment, material inconsistencies, or inaccurate cutting can occur. Identifying and resolving these issues quickly helps ensure smooth production and high-quality output.
Troubleshooting Guide for Door Frame Roll Forming Machines
| Issue | Possible Cause | Solution |
|---|---|---|
| Profile Distortion or Irregular Bends | Misaligned rollers, improper pressure settings | Adjust roller alignment and ensure uniform pressure distribution |
| Inconsistent Hole Punching | Faulty hydraulic system or misaligned punching dies | Check hydraulic pressure and realign punching dies for accuracy |
| Material Slippage During Forming | Loose feeder rollers or incorrect tension settings | Tighten feeder rollers and adjust material tension |
| Excessive Machine Vibration | Loose bolts, unstable foundation | Secure machine components and ensure a stable installation |
| Cutting Inaccuracy | Worn-out cutting blades or misaligned cutters | Replace dull blades and align cutters properly |
Pro Tip: Regular roller realignment and servo-driven adjustments can improve door frame accuracy by 30%.
Future Trends in Door Frame Roll Forming Machines
With the rapid evolution of Industry 4.0, door frame roll forming machines are becoming faster, smarter, and more efficient. Manufacturers are integrating AI, IoT, and automation to enhance productivity and precision.
Key Innovations in Door Frame Roll Forming Machines for 2025
1. AI-Controlled Quality Inspection
- AI-powered sensors detect defects in real-time, reducing waste.
- Improves product accuracy and minimizes rejection rates.
2. IoT & Smart Factory Integration
- Machines now feature cloud connectivity, allowing remote monitoring and predictive maintenance.
- Enhances real-time data tracking and performance optimization.
3. Servo-Driven Roll Forming Technology
- Improves speed control, accuracy, and energy efficiency.
- Reduces wear and tear on mechanical components.
4. Fully Automated Profile Adjustments
- Traditional machines require manual adjustments when switching door frame sizes.
- Advanced systems use CNC-driven auto-adjustments, reducing downtime.
Upgrading to AI-powered roll forming machines can increase production efficiency by up to 50%!
Roll Forming vs. Press Braking for Door Frame Production
When comparing roll forming and press braking, manufacturers must consider production speed, material waste, and cost efficiency.
Comparison Between Roll Forming and Press Braking for Door Frames
| Feature | Roll Forming | Press Braking |
|---|---|---|
| Process Type | Continuous shaping | Individual bending per sheet |
| Production Speed | Faster for long, continuous profiles | Slower for custom bends |
| Material Waste | Minimal waste | Higher material scrap |
| Tooling Costs | Higher initial investment, lower long-term cost | Lower upfront cost, higher operational cost |
| Best For | High-volume, industrial production | Custom, low-volume metal components |
Verdict: If you require high-speed, continuous production with minimal waste, door frame roll forming is the better choice.
Automation in Door Frame Roll Forming Machines
Automation is revolutionizing the manufacturing process, making roll forming machines smarter, faster, and more efficient.
Key Benefits of Automated Door Frame Roll Forming Machines
| Feature | Benefit |
|---|---|
| PLC & CNC Control Systems | Ensures precise measurements and minimizes human error |
| AI-Based Defect Detection | Identifies issues in real-time, reducing material waste |
| IoT & Remote Monitoring | Allows operators to track machine performance from anywhere |
| Automated Profile Changeover | Reduces downtime when switching between profiles |
| Energy-Efficient Servo Motors | Lowers operational costs and improves sustainability |
Fully automated door frame roll forming machines from Sunway Machine improve production efficiency by up to 40%!
Essential Maintenance Tips for Door Frame Roll Forming Machines
Proper maintenance ensures longer machine lifespan and uninterrupted production.
Maintenance Checklist for Door Frame Roll Forming Machines
| Task | Frequency | Purpose |
|---|---|---|
| Lubricate Rollers & Bearings | Weekly | Prevents wear and tear |
| Check Roller Alignment | Monthly | Ensures accurate profile production |
| Inspect Cutting Mechanism | Quarterly | Prevents defective cuts and misalignment |
| Clean Machine Components | Daily | Removes dust and debris that can affect performance |
| Update Software & Calibration | Semi-Annually | Keeps automation functions optimized |
Pro Tip: Scheduled maintenance can extend machine lifespan by 50% and reduce failures by 70%.
FAQ: Door Frame Roll Forming Machines
1. How fast can a door frame roll forming machine produce profiles?
High-speed models can produce up to 30 meters per minute, depending on the profile.
2. What door frame sizes can be produced?
Most machines can produce door frames ranging from 50mm to 300mm in width.
3. How much does a door frame roll forming machine cost?
The price ranges from 10,000forbasicmodels∗∗to∗∗10,000 for basic models** to **10,000forbasicmodels∗∗to∗∗300,000 for fully automated quick-change systems.
4. What materials can be used in door frame roll forming machines?
Common materials include galvanized steel, cold-rolled steel, stainless steel, and aluminum.
5. Where can I buy a high-quality door frame roll forming machine?
For custom-built, high-speed door frame roll forming machines, visit WUXI SUNWAY MACHINERY CO., LTD.
Final Thoughts
Investing in a door frame roll forming machine is essential for efficient, high-quality door frame production. Whether you need a standard or fully automated system, choosing a trusted manufacturer ensures long-term reliability and profitability.
WUXI SUNWAY MACHINERY CO., LTD is a leading global manufacturer of custom-built door frame roll forming machines, offering advanced technology, expert support, and competitive pricing.
Want a custom door frame roll forming machine? Contact us today!
