Metal forming processes play a crucial role in powering our society, driving innovation across industries. They enable the creation of a wide range of products and components, from heavy machinery and infrastructure to cutting-edge technologies like microprocessors and artificial intelligence.
But have you ever wondered how metal is shaped? In metal manufacturing, there are multiple processes to choose from. Each process holds its own set of advantages and disadvantages, making them suitable for specific applications and different types of metal.
Some of the most common types of metal forming techniques are:
- Roll forming
- Extrusion
- Press braking
- Stamping
- Forging
- Casting
Explore the diverse world of metal manufacturing processes and discover the optimal techniques for shaping metal to meet your unique needs.
1. Roll Forming
In short, roll forming involves continually feeding a long strip of metal through drum rollers to attain the desired cross-section. This process is highly efficient and cost-effective, making it the preferred choice for producing long lengths of sheet metal with consistent profiles. Additionally, roll forming can handle various metals such as steel, aluminum, copper, and more.
Roll forming services:
- Allow for advanced inline addition of punched features and embossing
- Are best suited for large volumes
- Yield complex profiles with intricate bending
- Have tight, repeatable tolerances
- Have flexible dimensions
- Create pieces that can be cut to any length
- Require little tool maintenance
- Are capable of forming high-strength metals
- Permit ownership of tooling hardware
- Reduce room for error
- Create less scrap
Common Industries & Applications of Roll Forming
Industries
Aerospace
Appliance
Automotive
Construction
Energy
Fenestration
HVAC
Metal Building Products
Solar
Tube & Pipe
Common Applications
- Construction Equipment
- Door Components
- Elevators
- Framing
- HVAC
- Ladders
- Mounts
- Railings
- Ships
- Structural Components
- Tracks
- Trains
- Tubing
- Windows
2. Extrusion
Extrusion is a metal manufacturing process that forces metal through the die of the desired cross-section. It creates complex cross-sections and hollow parts with uniform wall thicknesses. Extrusion is a favored process for producing long lengths of metal with intricate cross-sectional profiles, and it's also highly efficient.
If you're thinking of pursuing extrusion metal forming, you should keep in mind that:
- Aluminum is primarily the extrusion of choice, though most other metals can be used
- Dies (aluminum) are relatively affordable
- Punching or embossing is done as a secondary operation
- It can produce hollow shapes without seam welding
- It can produce complex cross-sections
Common Industries & Applications of Extrusion
Industries
- Agriculture
- Architecture
- Construction
- Consumer Goods Manufacturing
- Electronics Manufacturing
- Hospitality
- Industrial Lighting
- Military
- Restaurant or Food Service
- Shipping & Transportation
Common Applications
- Aluminum Cans
- Bars
- Cylinders
- Electrodes
- Fittings
- Frames
- Fuel Supply Lines
- Injection Tech
- Rails
- Rods
- Structural Components
- Tracks
- Tubing
3. Press Braking
Press braking involves common sheet metal forming (usually), bending the metal workpiece to a predetermined angle by pinching it between a punch and a die. Press brakes are commonly used to bend metal sheets into V or U shapes for architectural, automotive, and other purposes.
If you're interested in press braking, be aware that it:
- Works best for shorter, smaller runs
- Produces shorter parts
- Is best suited for compatible shapes with more simple bend patterns
- Has a high associated labor cost
- Produces less residual stress than roll forming
Common Industries & Applications of Press Breaking
Industries
- Architecture
- Construction
- Electronics Manufacturing
- Industrial Manufacturing
Common Applications
- Decorative or Functional Trim
- Electronics Enclosures
- Housings
- Safety Features
4. Stamping
Stamping involves placing a flat metal sheet (or coil) into a stamping press, where a tool and die apply pressure to form the metal into a new shape or cut out a piece of the metal. Stamping is ideal for producing high volumes of parts with consistent, intricate designs.
Stamping is associated with:
- Single-press stroke forming
- Consistent pieces with fixed dimensions
- Shorter parts
- Higher volumes
- Creating complex parts in a short amount of time
- Requiring high-tonnage presses
Common Industries & Applications of Stamping
Industries
- Appliances Manufacturing
- Construction
- Electrical Manufacturing
- Hardware Manufacturing
- Fastenings Manufacturing
Common Applications
- Aircraft Components
- Ammunitions
- Appliances
- Blanking
- Electronics
- Engines
- Gears
- Hardware
- Lawn Care
- Lighting
- Lock Hardware
- Power Tools
- Progressive Die Stamping
- Telecom Products
5. Forging
Forging involves shaping metals using localized, compressive forces after heating the metal to a point where it's malleable. This process yields strong, durable parts that are resistant to wear and tear.
If you're considering forging, keep in mind that:
- Precision forging combines production and manufacturing by forming the raw material into the desired shape, with the lowest possible amount of secondary operations needed
- It requires little to no subsequent fabrications
- It requires high tonnage presses
- It yields a stronger end product
- It results in a product with high strength and hardness
Common Industries & Applications of Forging
Industries
- Aerospace
- Automotive
- Medical
- Power Generation & Transmission
Applications
- Axle Beams
- Ball Joints
- Couplings
- Drill Bits
- Flanges
- Gears
- Hooks
- Kingpins
- Landing Gear
- Missiles
- Shafts
- Sockets
- Steering Arms
- Valves
6. Casting
Casting is a process that involves pouring liquid metal into a mold containing a hollow cavity of the desired shape. As the liquid cools and solidifies, it takes on the shape of the mold. Casting is ideal for complex shapes and designs with intricate details that would be difficult or expensive to produce through other metal forming processes.
Those considering utilizing a casting metal forming process should keep in mind that it:
- Can use a wide range of alloys & custom alloys
- Results in affordable short-run tooling
- Can result in products with high porosity
- Is best suited for smaller runs
- Can create complex parts
Common Industries & Applications of Casting
Industries
- Alternative Energy
- Agriculture
- Automotive
- Construction
- Culinary
- Defense & Military
- Health Care
- Mining
- Paper Manufacturing
Common Applications
- Appliances
- Artillery
- Art items
- Camera Bodies
- Casings, Covers
- Diffusers
- Heavy Equipment
- Motors
- Prototyping
- Tooling
- Valves
- Wheels
Choosing A Metal Forming Method
Are you looking for a metal former for your project? The type of metal manufacturing method you choose will depend on many factors:
- What metal are you using?
- What's your budget?
- What do you need to create?
- How will it be used?
By understanding the different metal manufacturing processes available and their applications, you can make informed decisions when choosing the most suitable technique for your specific project requirements.
Is Roll Forming Right for You?
If your metal shaping needs demand high volume, intricate profiles, and exceptional durability, roll forming is a powerful solution worth exploring. Its efficiency, precision, and flexibility can significantly enhance your production processes and deliver superior-quality products. With its ability to both optimize existing designs and unlock innovative possibilities, roll forming is a valuable tool for any manufacturer looking to stay ahead in today's competitive landscape.
Find out why so many industries choose roll forming and if the process fits your needs. Check out our free guide:
(Editor's Note: This article was originally published in January 2017 and was recently updated.)
5 Different Types of Metal Forming Processes
Although there are many
It is a continuous operation in which a long strip of metal (typically coiled steel) is passed through a series of pairs of rolls or stands, each set performing only an incremental part of the bend until the desired cross-section profile is obtained. Roll forming is performed at room temperature and can be used to form metals into a large variety of different shapes and sizes.
How Can Material Manufacturers and Steel Fabricators take Advantage of Roll Forming?
You must consider how steel fabricators and material manufacturers can take advantage of roll forming. Material manufacturers can take advantage of roll forming by using it to produce parts with different physical or mechanical properties. For example, they can use roll forming to produce parts that are more wear-resistant or have a higher strength-to-weight ratio.
In addition, steel fabricators can use roll forming to produce parts with more complex geometry. Fabricators usually have to work with a variety of different metals, including both cold-rolled and hot-rolled metals.
But what if there was a way to use roll forming to create parts from both types of metals?
Well, there is!
In fact, many steel fabricators have already adopted this method and are using it to create special profiles. Roll forming is slightly used in the fabrication industry however; bending is the more dominant method. Fabricators generally use roll-formed products like sheet metal; I, U & H profiles, circular and rectangular hollow sections. These hot-formed products are then fabricated into strut channels, metal door frames, automotive body panels, solar racking, etc.
Advantages: The advantages of roll forming over other metal forming processes include:
- Ability to produce complex shapes with minimum tooling.
- Form metals with high strength-to-weight ratios.
- Versatility in forming a wide range of different metals.
- A continuous process that leads to high production rates.
- Generates little scrap.
- Easy to handle.
Disadvantages: The process also has some disadvantages, including the following:
- Limited to metals that can be cold-rolled.
- Not well suited for metals with high yield strength.
Although there are many types of metal forming processes , they can be broadly classified into five main categories:It is a continuous operation in which a long strip of metal (typically coiled steel) is passed through a series of pairs of rolls or stands, each set performing only an incremental part of the bend until the desired cross-section profile is obtained. Roll forming is performed at room temperature and can be used to form metals into a large variety of different shapes and sizes.You must consider how steel fabricators and material manufacturers can take advantage of roll forming. Material manufacturers can take advantage of roll forming by using it to produce parts with different physical or mechanical properties. For example, they can use roll forming to produce parts that are more wear-resistant or have a higher strength-to-weight ratio.In addition, steel fabricators can use roll forming to produce parts with more complex geometry. Fabricators usually have to work with a variety of different metals, including both cold-rolled and hot-rolled metals.But what if there was a way to use roll forming to create parts from both types of metals?Well, there is!In fact, many steel fabricators have already adopted this method and are using it to create special profiles. Roll forming is slightly used in the fabrication industry however; bending is the more dominant method. Fabricators generally use roll-formed products like sheet metal; I, U & H profiles, circular and rectangular hollow sections. These hot-formed products are then fabricated into strut channels, metal door frames, automotive body panels, solar racking, etc.The advantages of roll forming over other metal forming processes include:The process also has some disadvantages, including the following: