What is CNC Roll Forming?<\/h2>\n\n\n\n
Roll forming is a continuous bending process in which sheet or strip metal is gradually formed into a desired cross-sectional profile through a series of consecutive roller stations. As the material passes through each roller station, it is incrementally shaped into the desired form.<\/p>\n\n\n\n
CNC roll forming incorporates computer numerical control technology to automate the roll forming process. CNC systems control all aspects of the roll forming machine, including roller position, metal feed rate, and other parameters. Operators simply program the desired specifications into the CNC controller and the machine automatically adjusts the roller stations to shape the material accordingly.<\/p>\n\n\n\n
Some key benefits of CNC roll forming:<\/p>\n\n\n\n
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- Highly accurate and consistent output. CNC automation ensures every part meets specifications.<\/li>\n\n\n\n
- Flexible and easy changeovers between different cross-sections. Operators just load a new program.<\/li>\n\n\n\n
- Higher throughput and productivity compared to manual roll forming.<\/li>\n\n\n\n
- Minimal operator supervision required after initial setup.<\/li>\n\n\n\n
- Capable of complex profiles that would be difficult with manual roll forming.<\/li>\n<\/ul>\n\n\n\n
CNC enables roll forming machines to deliver precision and efficiency beyond the capabilities of manual operations. This has led to the widespread adoption of CNC roll forming technology across many industries.<\/p>\n\n\n\n
![\"cnc](\"https:\/\/swforming.com\/wp-content\/uploads\/2023\/08\/Rolling-Shutter-Slat-Roll-Forming-Machine-01.webp\" "\\"\\"")
Rolling Shutter Slat Roll Forming Machine<\/figcaption><\/figure>\n\n\n\n Major Application Areas of CNC Roll Forming<\/h2>\n\n\n\n
CNC roll forming machines have become ubiquitous in manufacturing sectors where long sheet metal components are required. Some of the most common applications include:<\/p>\n\n\n\n
Building and Construction<\/h3>\n\n\n\n
CNC roll forming is widely used to produce metal studs, joists, purlins, wall panels, roofing, decking, and various architectural claddings. Construction applications require long, lightweight sections that can be mass-produced efficiently.<\/p>\n\n\n\n
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- Metal studs<\/strong> – Load-bearing interior wall framing members. CNC lines can produce galvanized steel studs in different thicknesses and lengths.<\/li>\n\n\n\n
- Roofing and siding<\/strong> – Roll formed metal panels for roofs, exterior walls, and fa\u00e7ades. CNC lines produce long sheets with specialized ribbing for strength and interlocking.<\/li>\n\n\n\n
- Solar mounting structures<\/strong> – Formed metal parts for solar panel frames and sun tracking systems. Complex CNC profiles required for structural stability.<\/li>\n<\/ul>\n\n\n\n
Transportation<\/h3>\n\n\n\n
Automotive, truck, trailer, and railcar manufacturers utilize roll formed sections for vehicle frames, interiors, and exterior body panels. CNC roll forming allows high-volume production with precision.<\/p>\n\n\n\n
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- Chassis frames<\/strong> \u2013 Roll formed side rails and cross members used in truck and trailer bodies. CNC enables complex bends.<\/li>\n\n\n\n
- Automotive panels<\/strong> \u2013 Exterior body panels are roll formed into smooth, aerodynamic shapes.<\/li>\n\n\n\n
- Interiors<\/strong> – Interior door frames, seat frames, and roof arches are roll formed for cars and trains.<\/li>\n<\/ul>\n\n\n\n
Appliances<\/h3>\n\n\n\n
Home appliances often contain roll formed metal enclosures, frames, and structural components. The housings of refrigerators, washers, dryers, air conditioners, and many other appliances are produced on CNC roll lines.<\/p>\n\n\n\n
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- Washing machine drums<\/strong> \u2013 Formed end caps and tub frames maintain roundness.<\/li>\n\n\n\n
- Refrigerator liners<\/strong> \u2013 Interior stainless steel liners shaped to exact dimensions.<\/li>\n\n\n\n
- Air conditioner chassis<\/strong> \u2013 Structural side frames and bottom panels.<\/li>\n<\/ul>\n\n\n\n
Infrastructure<\/h3>\n\n\n\n
From light poles to guardrails, infrastructure projects utilize a range of roll formed sections. CNC automation allows mass production of consistent street furniture components.<\/p>\n\n\n\n
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- Light poles<\/strong> \u2013 Tapered pole shafts and arms are formed from sheet steel.<\/li>\n\n\n\n
- Traffic barriers<\/strong> \u2013 Guardrails and highway barriers made of roll formed steel.<\/li>\n\n\n\n
- Utility poles<\/strong> \u2013 Transmission line poles and cell tower shafts require angled profiles.<\/li>\n<\/ul>\n\n\n\n
Furniture<\/h3>\n\n\n\n
Many modern furniture designs incorporate metal frames and structural elements that are ideal for roll forming. CNC allows both long production runs and custom short runs.<\/p>\n\n\n\n
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- Desks<\/strong> \u2013 CNC lines produce sturdy steel desk legs and structural beams.<\/li>\n\n\n\n
- Chairs<\/strong> \u2013 Formed seat and back support frames for metal chairs.<\/li>\n\n\n\n
- Shelving<\/strong> \u2013 Upright support posts and horizontal shelves.<\/li>\n<\/ul>\n\n\n\n
Key Components of CNC Roll Forming Lines<\/h2>\n\n\n\n
A CNC roll forming system contains a number of key components that work together to shape sheet metal stock into the desired forms. Here are some of the main elements:<\/p>\n\n\n\n
Feed Mechanism<\/h3>\n\n\n\n
The feed mechanism provides consistent feeding of sheet or coil stock into the roll forming section. This typically consists of powered pinch roller feeds or servo-motor driven feeds. The CNC control coordinates the feed rate to match the forming speed.<\/p>\n\n\n\n
Forming Section<\/h3>\n\n\n\n
The forming section consists of a series of roller stations that progressively bend and shape the strip stock. Advanced CNC roll forming lines have servo-driven roller stations that can be digitally positioned for precision forming and rapid changeovers.<\/p>\n\n\n\n
CNC Controller<\/h3>\n\n\n\n
The CNC controller executes the roll forming program and coordinates all machine motions and functions. Operators simply call up programs for different parts or profiles. The CNC ensures repeatable and accurate execution.<\/p>\n\n\n\n
Cutoff Station<\/h3>\n\n\n\n
A final cutoff press or shear cuts the finished roll formed parts to the desired lengths as they exit the machine. The cutoff operation can also be integrated into the CNC control programming.<\/p>\n\n\n\n
Outfeed Equipment<\/h3>\n\n\n\n
Outfeed tables, conveyors, stacking systems, or robotic arms manage and collect finished parts as they are produced. This automation can be integrated with the overall CNC control system.<\/p>\n\n\n\n
Safety Enclosure<\/h3>\n\n\n\n
Full perimeter guarding and safety fencing ensures operator protection. Advanced systems have interlocks preventing the machine from operating without guards in place.<\/p>\n\n\n\n
By combining all these elements under integrated CNC control, modern roll forming lines achieve rapid changeover, high productivity, and precision output during unattended production.<\/p>\n\n\n\n
Advantages of CNC Roll Forming Technology<\/h2>\n\n\n\n
CNC roll forming machines deliver significant benefits that explain their widespread adoption across manufacturing:<\/p>\n\n\n\n
Enhanced Precision and Consistency<\/h3>\n\n\n\n
With CNC control, roll forming machines produce parts within extremely tight tolerances of 0.005 inches (0.127mm) or better. This precision ensures consistency across high production volumes.<\/p>\n\n\n\n
Flexible and Efficient Changeovers<\/h3>\n\n\n\n
Operators can switch to new roll formed profiles in minutes by simply selecting new programs. No hardware changeovers required.<\/p>\n\n\n\n
Increased Throughput<\/h3>\n\n\n\n
CNC automation enables roll forming lines to operate at high production speeds around 100 ft\/min (30 m\/min) while maintaining synchronous material feed.<\/p>\n\n\n\n
Ability to Form Complex Shapes<\/h3>\n\n\n\n
With servo-controlled roll stations, even intricately shaped sections with multiple bends along multiple axes can be roll formed.<\/p>\n\n\n\n
Minimal Material Waste<\/h3>\n\n\n\n
CNC programming compensates for material springback, resulting in accurate forms with less trial and error and material waste.<\/p>\n\n\n\n
Reduced Labor Requirements<\/h3>\n\n\n\n
Automated CNC roll forming lines require just one or two operators for setup and supervision during production.<\/p>\n\n\n\n
Lower Operational Costs<\/h3>\n\n\n\n
Consistent quality and high output with less labor results in lower overall part costs.<\/p>\n\n\n\n
With all these advantages, it’s easy to see why CNC roll forming represents the state of the art in metal forming technology.<\/p>\n\n\n\n
![\"cnc](\"https:\/\/swforming.com\/wp-content\/uploads\/2023\/08\/Rolling-Shutter-Slat-Roll-Forming-Machine-05.webp\" "\\"\\"")
<\/figcaption><\/figure>\n\n\n\n CNC Roll Forming Machine Configurations<\/h2>\n\n\n\n
CNC roll forming machines are built in different configurations to suit various production needs. Key factors determining machine design include part length, material thickness, and output rates.<\/p>\n\n\n\n
Continuous vs Cut-to-Length<\/h3>\n\n\n\n
Continuous roll forming produces strip stock of indefinite length, wound onto a takeup reel. Cut-to-length lines shear finished parts at predetermined intervals.<\/p>\n\n\n\n
Horizontal vs Vertical Orientation<\/h3>\n\n\n\n
Horizontally fed machines occupy less floor space while vertical machines allow gravity-assisted feeding.<\/p>\n\n\n\n
Single vs Multi-Profile<\/h3>\n\n\n\n
Some lines produce a single profile while tandem and modular machines can quickly switch between different forms.<\/p>\n\n\n\n
In-Line vs Standalone<\/h3>\n\n\n\n
In-line machines are integrated into larger production systems while standalone configurations allow for flexible use.<\/p>\n\n\n\n
Heavy-Gauge Capability<\/h3>\n\n\n\n
Some roll forming lines specialize in heavier gauge metals or stainless steels using more robust components.<\/p>\n\n\n\n
With experience and expertise, roll forming machine builders can configure CNC lines optimized for customer requirements. Customized lines ensure optimal productivity.<\/p>\n\n\n\n
Programming and Setups<\/h2>\n\n\n\n
Efficient CNC roll former operation relies on proper programming and setup. Machine builders offer programming services and CAD software options to facilitate the process.<\/p>\n\n\n\n
3D Model to Machine Program<\/h3>\n\n\n\n
Part designs are modeled in 3D CAD and then software converts geometries into machine code for each roller position.<\/p>\n\n\n\n
Machine Calibration<\/h3>\n\n\n\n
Roller stations go through automatic initial calibration routines to align positions to CNC zero points and axes.<\/p>\n\n\n\n
Material Properties<\/h3>\n\n\n\n
Unique material characteristics like modulus of elasticity are input into software to factor in material springback.<\/p>\n\n\n\n
Forming Sequence Optimization<\/h3>\n\n\n\n
The order of bends and forms can be optimized to avoid material defects and stresses.<\/p>\n\n\n\n
Simulation and Emulation<\/h3>\n\n\n\n
Offline programming can simulate machine movements and detect interferences before live runoff.<\/p>\n\n\n\n
Tooling Design<\/h3>\n\n\n\n
Specialized tooling like bend rolls, presses, guides, and gauges may be required for certain profiles.<\/p>\n\n\n\n
With the proper preparation, CNC roll forming machines can accurately produce a new profile on the first pass.<\/p>\n\n\n\n
Quality Control Systems<\/h2>\n\n\n\n
To leverage the full potential of CNC roll forming lines, automated quality control systems are often implemented. These include:<\/p>\n\n\n\n
Servo Rollforce Monitoring<\/h3>\n\n\n\n
Force sensors on servo rolls detect fluctuations indicating defects. The CNC control can adjust in real-time or flag bad parts.<\/p>\n\n\n\n
Automatic Dimensional Inspection<\/h3>\n\n\n\n
Laser or optical sensors mounted along the line inspect key dimensions and check for forming errors.<\/p>\n\n\n\n
Post-Production Gauge Testing<\/h3>\n\n\n\n
Sample parts are measured against precision gauges. Automated gauges can be integrated into the production line.<\/p>\n\n\n\n
Vision Inspection<\/h3>\n\n\n\n
Machine vision systems check for surface defects and inconsistencies in the material. Automated sorting systems cull bad parts.<\/p>\n\n\n\n
CMM Part Scanning<\/h3>\n\n\n\n
Sample parts are placed in a CMM scanner for 360-degree dimensional analysis. Data informs process improvements.<\/p>\n\n\n\n
Advanced CNC roll forming lines function as fully-automated turnkey systems with integrated quality verification at every stage. This represents the pinnacle of roll forming technology.<\/p>\n\n\n\n
Latest Advancements in CNC Roll Forming<\/h2>\n\n\n\n
As an evolving technology, CNC roll forming systems are continually incorporating the latest innovations and enhancements. Some current developments include:<\/p>\n\n\n\n
Servo Electric Actuation<\/h3>\n\n\n\n
Replacing traditional hydraulic roller positioning with fast and precise servo electric actuation for higher speeds and accuracies.<\/p>\n\n\n\n
On-the-Fly Adjustments<\/h3>\n\n\n\n
Real-time monitoring and automatic roller adjustments on the fly to compensate for material variations and improve consistency.<\/p>\n\n\n\n
Advanced Safety Features<\/h3>\n\n\n\n
Innovations like multi-spectrum 3D vision fully eliminate potential contact points through proactive detection and controlled shutdown.<\/p>\n\n\n\n
Connected Remote Access<\/h3>\n\n\n\n
Monitoring line status and part quality metrics in real-time from anywhere. Making live programming adjustments remotely.<\/p>\n\n\n\n
Rapid Changeover Tooling<\/h3>\n\n\n\n
Quick release tooling systems and fast roller change carts enable profile adjustments in under 10 minutes.<\/p>\n\n\n\n
Energy Efficient “Green” Machines<\/h3>\n\n\n\n
Next-generation lines leverage efficiencies of servo-electric actuation for reduced energy consumption and lower environmental impact.<\/p>\n\n\n\n
Customized Smart Factories<\/h3>\n\n\n\n
Fully-tailored Industry 4.0 production lines integrate data collection, connected sensors, analytics, and machine learning capabilities.<\/p>\n\n\n\n
With constant material and technological innovations, CNC roll forming systems will continue pushing boundaries and exploring new applications across manufacturing.<\/p>\n\n\n\n
Roll Forming Versus Other Metal Fabrication Methods<\/h2>\n\n\n\n
While roll forming provides substantial advantages, it is just one of many metal working processes available. Other common fabrication methods include:<\/p>\n\n\n\n
Stamping<\/h3>\n\n\n\n
Stamping utilizes presses and dies to form sheet metal with high tonnages of pressure. Lower volumes due to higher tooling costs.<\/p>\n\n\n\n
Hydroforming<\/h3>\n\n\n\n
Forming metal into complex tubular and enclosed shapes using highly pressurized fluid. Limited profile shapes but ideal for automotive pipes and tubes.<\/p>\n\n\n\n
Welding Fabrication<\/h3>\n\n\n\n
Joining metal pieces together along seams through arc or spot welding. Labor intensive technique.<\/p>\n\n\n\n
Brake Forming<\/h3>\n\n\n\n
Bending sheet metal into forms using mechanical braking press. Slower and more tooling intensive than roll forming.<\/p>\n\n\n\n
Casting<\/h3>\n\n\n\n
Pouring molten metal into molds to create solidified forms. Ideal for high-volume parts with detailed features like engine blocks.<\/p>\n\n\n\n
Extrusion<\/h3>\n\n\n\n
Squeezing metal through a die to create lengths with fixed cross-section. Limited to simplistic profiles.<\/p>\n\n\n\n
For producing long lengths of sheet metal into open symmetric cross-sections, roll forming provides distinct advantages over these other processes.<\/p>\n\n\n\n
![\"cnc](\"https:\/\/swforming.com\/wp-content\/uploads\/2023\/07\/Hydraulic-Roof-Sheet-Curving-Machine-01.webp\" "\\"\\"")
Hydraulic Roof Sheet Curving Machine 01<\/figcaption><\/figure>\n\n\n\n FAQ<\/h2>\n\n\n\n
What types of metals can be roll formed?<\/p>\n\n\n\n
Most ductile metals can be roll formed, including steel, stainless steel, aluminum, copper, and brass. The ability to withstand bending without cracking is the key requirement.<\/p>\n\n\n\n
What are common roll formed end product examples?<\/p>\n\n\n\n
Gutters, roofing, siding, racks, rails, framing studs, vehicle panels, highway signage, billboards, shelving, enclosures, solar panel frames, and LED light housings are some examples of roll formed end products.<\/p>\n\n\n\n
What thicknesses of metals can be roll formed?<\/p>\n\n\n\n
Standard roll formers can typically process metal from 26 gauge (0.017\u201d) up to about 14 gauge (0.075\u201d) thickness. Extended ranges up to 1\u20444\u201d thick material are also possible with heavy-gauge roll forming machines.<\/p>\n\n\n\n
How are complex roll formed shapes possible?<\/p>\n\n\n\n
By shaping material progressively through a series of bending steps in multiple directions rather than all at once, even intricate forms can be produced. The ultimate form is the sum of numerous small incremental bends.<\/p>\n\n\n\n
Can a single roll forming machine make different profiles?<\/p>\n\n\n\n
Some configurable or modular machines can be equipped with additional tooling sets and CNC programs to enable quick profile changeovers. Standardized designs also allow retrofitting existing lines with new tooling.<\/p>\n\n\n\n
What size production runs are optimal for roll forming?<\/p>\n\n\n\n
Long production runs over 50,000 linear feet is where the efficiency of CNC roll forming provides the most advantage. However, short prototype and small batch runs are also feasible.<\/p>\n\n\n\n
How does roll forming compare to 3D metal printing?<\/p>\n\n\n\n
While additive manufacturing can produce highly complex one-off shapes, roll forming is superior for mass production of simple long metal sections in the 1,000+ piece range. The two technologies can complement each other.<\/p>\n\n\n\n
Conclusion<\/h2>\n\n\n\n
CNC roll forming provides transformative benefits for producing metal parts with long, open cross-sections. With unparalleled efficiencies, flexibility, precision, and cost-effectiveness, CNC roll forming machines have become integral to manufacturing across diverse industries.<\/p>\n\n\n\n
Ongoing advancements are unlocking even greater potential for this technology. As engineering innovations continue, CNC roll forming systems will take on more applications and play an expanding role in automated smart factories of the future. The widespread adoption of this technology is a testament to the capabilities it brings to the manufacturing sector.<\/p>\n\n\n\n
know more Roll forming<\/a><\/p>\n\n\n\n
Frequently Asked Questions (FAQ)<\/h2>\n\n\n\n
1) How does a CNC roll forming machine differ from a conventional roll former?<\/p>\n\n\n\n
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- CNC systems control stand positions, feed rates, cutoff timing, and integrated punching via recipes, enabling faster changeovers, tighter tolerances, and repeatable quality versus manual or semi-automatic lines.<\/li>\n<\/ul>\n\n\n\n
2) What tolerances can modern CNC roll forming machines achieve?<\/p>\n\n\n\n
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- With servo stands, laser length measurement, and recipe compensation for springback, typical tolerances are \u00b10.15\u20130.30 mm on critical dimensions and \u00b10.5\u20131.0 mm on cut length at 3 m, depending on material and profile.<\/li>\n<\/ul>\n\n\n\n
3) Can a single CNC line handle multiple profiles and materials?<\/p>\n\n\n\n
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- Yes. Cassette tooling and stored CNC recipes allow switching among stud\/track sizes, purlins, or appliance rails and between GI, ZM (Zn-Al-Mg), aluminum, and some AHSS. Expect minor setup checks for roll gaps and lubricants.<\/li>\n<\/ul>\n\n\n\n
4) What inline operations can be integrated on a CNC roll forming machine?<\/p>\n\n\n\n
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- Commonly: servo punching\/notching, embossing, labeling\/inkjet marking, thread-forming, clinching, spot welding, and inline quality checks (laser geometry, vision for hole patterns) all synchronized via the CNC.<\/li>\n<\/ul>\n\n\n\n
5) How do I estimate production rate for a given profile?<\/p>\n\n\n\n
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- Line speed is bounded by material thickness, hole density, and cutoff type. For 0.6\u20131.0 mm GI studs with moderate punching, 60\u2013120 m\/min is typical; heavy-gauge purlins (2.0\u20133.0 mm) run 20\u201360 m\/min with flying shear.<\/li>\n<\/ul>\n\n\n\n
2025 Industry Trends for CNC Roll Forming Machines<\/h2>\n\n\n\n
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- Digital twins and FEA-first \u201cflower\u201d design cut commissioning time by 20\u201340% and reduce first\u2011article scrap.<\/li>\n\n\n\n
- Broader use of Zn\u2011Al\u2011Mg coated steel and 3rd\u2011gen AHSS in construction and transportation profiles.<\/li>\n\n\n\n
- Sub\u201120\u2011minute changeovers via servo stand positioning, quick-change cassettes, and automated recipe recall.<\/li>\n\n\n\n
- Closed-loop quality: inline laser metrology and AI vision flag drift, auto-adjust stands\/cutoff in real time.<\/li>\n\n\n\n
- Energy optimization: regenerative drives and ISO 50001 reporting; kWh\/ton is now a tracked KPI.<\/li>\n\n\n\n
- Safety and compliance upgrades: ISO 13849 performance level d, UL\/CE electrics, lockout analytics.<\/li>\n\n\n\n
- MES integration standardizes traceability from coil lot to bundle ID for building codes and OEM PPAP.<\/li>\n<\/ul>\n\n\n\n
2025 Benchmarks and Adoption Metrics<\/h3>\n\n\n\n
- Line speed is bounded by material thickness, hole density, and cutoff type. For 0.6\u20131.0 mm GI studs with moderate punching, 60\u2013120 m\/min is typical; heavy-gauge purlins (2.0\u20133.0 mm) run 20\u201360 m\/min with flying shear.<\/li>\n<\/ul>\n\n\n\n
- Commonly: servo punching\/notching, embossing, labeling\/inkjet marking, thread-forming, clinching, spot welding, and inline quality checks (laser geometry, vision for hole patterns) all synchronized via the CNC.<\/li>\n<\/ul>\n\n\n\n
- Yes. Cassette tooling and stored CNC recipes allow switching among stud\/track sizes, purlins, or appliance rails and between GI, ZM (Zn-Al-Mg), aluminum, and some AHSS. Expect minor setup checks for roll gaps and lubricants.<\/li>\n<\/ul>\n\n\n\n
- With servo stands, laser length measurement, and recipe compensation for springback, typical tolerances are \u00b10.15\u20130.30 mm on critical dimensions and \u00b10.5\u20131.0 mm on cut length at 3 m, depending on material and profile.<\/li>\n<\/ul>\n\n\n\n
- Chairs<\/strong> \u2013 Formed seat and back support frames for metal chairs.<\/li>\n\n\n\n
- Traffic barriers<\/strong> \u2013 Guardrails and highway barriers made of roll formed steel.<\/li>\n\n\n\n
- Refrigerator liners<\/strong> \u2013 Interior stainless steel liners shaped to exact dimensions.<\/li>\n\n\n\n
- Automotive panels<\/strong> \u2013 Exterior body panels are roll formed into smooth, aerodynamic shapes.<\/li>\n\n\n\n
- Roofing and siding<\/strong> – Roll formed metal panels for roofs, exterior walls, and fa\u00e7ades. CNC lines produce long sheets with specialized ribbing for strength and interlocking.<\/li>\n\n\n\n
- Metal studs<\/strong> – Load-bearing interior wall framing members. CNC lines can produce galvanized steel studs in different thicknesses and lengths.<\/li>\n\n\n\n