Overview

An OEM metal roll forming machine is a versatile industrial equipment system used to efficiently mass produce long lengths of precision custom metal parts and profiles for original equipment manufacturers.

The continuous roll forming process shapes metal coil feedstock into various rails, frames, enclosures and structural components using a series of rotating roller dies.

This guide provides a comprehensive overview of OEM roll former technology, including:

• Machine types and components
• How the roll forming process works
• Design considerations
• End use applications
• Material and specification standards
• Cost analysis
• Comparisons with other metal fabrication methods

Gaining insight into OEM metal roll former capabilities assists manufacturers evaluating optimized production solutions for metal components used in specialized equipment and products.

Types of OEM Metal Roll Forming Machines

There are two primary machine configurations for high volume OEM parts production:

Fixed Head Roll Formers

• Typically 10-16 forming stations
• Common base profiles
• Lower tooling cost
• Repeat jobs

Quick Change Roll Formers

• Individual stations per head
• Flexible tooling for profile variations
• Higher output variety
• Frequent form changes

Main Components of a Metal Roll Former

A typical OEM metal roll forming system integrates these main sections:

Coil Payoff Reel

• Holds raw coil at unwind station
• Feeds strip through process

Entry Guides

• Align and straighten strip
• Optimize material feed

Accumulator/Bridle

• Creates back tension zone
• Smooths flow variations

Forming Stations

• Progressive die rollers shape material
• Number & type determine profile

Cutter

• Shears finished parts to length
• Pneumatic, servo electric

Exit Conveyor

• Transfers finished product
• Links to secondary operations

Automation Controls

• HMI and PLC hardware
• Touchscreen programming
• Data feedback

How Metal Roll Forming Machines Work

The OEM roll forming process shapes metal coil feedstock into rails, frames and custom profiles by bending and forming the strip material incrementally as it passes through a series of roller die stations:

1. Powered coil payoff reel feeds raw coiled strip into initial machine guides
2. Entry guides align strip and feed into first roller station
3. At each station, machined rollers make precision bends and forms
4. Strip exits slightly more formed moving to subsequent stations
5. Finished custom profile emerges at end of forming line
6. Profile cutoff to length by pneumatic or servo shear
7. Formed parts conveyed for additional fabrication

The number of roller die stations determines possible shape complexity. Quick changeovers accommodate low to high mix production.

Key Design Factors for OEM Roll Forming

Equipment specifiers evaluate numerous characteristics when selecting OEM metal roll formers:

Product Type

• Metal structural framing
• Equipment enclosures
• Machine bases and supports

Material

• Mild steel
• Stainless steel
• Aluminum
• Other alloys

Thickness

• 20 gauge to 1/4”
• 0.6 mm to 6 mm

Profile

• C & U channels
• Complex rails and frames
• Hollow box sections

Length

• Up to 30′ possible
• Exit tables for support

Speed

• 10 to 100+ feet/min
• Low vs high cycle times

Changeover

• Quick change tooling
• Repeatable accuracy

Automation

• Level required
• Data feedback

Floor Space

• Line length
• Layout constraints

Standards for OEM Roll Formed Metals

While having fewer universal specifications, these guidelines apply to certain OEM components:

Typical Applications for Roll Formed Metals

Common end uses for roll formed metals in original equipment include:

Electrical Equipment

• Motor and transformer frames
• Switchgear housings
• Generator enclosures

Machinery Structures

• Machine bases
• Robotic arm supports
• Conveyor frames

Commercial Appliances

• Refrigerator liners
• Range and oven cavities
• Washer and dryer drums

HVAC Components

• Furnace and AC housing
• Heat exchangers
• Ducting frames

Furniture

• Desk and cabinet frames
• Shelving posts and rails
• Table bases

White Goods

• Dishwasher tubs
• Clothes dryer cylinders
• Range oven cavity frames

Specifications

Manufacturers of oem metal roll forming machine

Leading global OEM metal roll former manufacturers include:

Pricing

Advantages of OEM Metal Roll Forming

Benefits

• High hourly production rates
• Precision tolerances
• Low operational costs
• Minimal secondary fabricating
• High material utilization
• Lean, continuous-flow process

Limitations

• Substantial initial capital costs
• Mostly long, straight geometries
• Tooling expensive for low volumes
• Can require secondary punching, welding, drilling

FAQ

What metals work with OEM roll forming?

All ductile metals can use roll forming including low carbon steel, stainless steel, aluminum, copper, and titanium alloys. Hardened materials may require specialized tooling.

What tolerances are possible with OEM roll formed parts?

Roll formed components can reliably achieve profile tolerances between +/- 0.1 mm to +/- 0.25 mm for quality machines depending on the material gauge.

How long can an OEM roll formed metal part be?

Standard maximums with support tables are around 18 meters (60 feet). Custom long bed machines can produce sections over 30 meters (100 feet).

How thick of metal can an OEM roll former handle?

Thicknesses from 0.15 mm (30 gauge) to about 6 mm (1/4 inch) are typical for an average OEM roll former. Beyond that may require custom heavy-duty equipment.

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