Roll forming bends a long strip of sheet metal step by step through a line of shaped rollers until it becomes a profile such as a C channel, Z purlin, angle, door frame or roofing sheet. It runs continuously from coil and cuts parts to length on the line, so it is very economical for large quantities of long, identical profiles.
Quick facts
- Input
- Sheet coil (CR, HR, GI, aluminium, stainless)
- Typical thickness
- About 0.3–4 mm (0.0118–0.157 inch); heavier on big lines
- Length
- Any length, cut on the line
- Tooling
- A set of roller dies per profile
- Speed
- Tens of metres per minute
- Best for
- Large quantities of one profile
Roll forming or press brake bending?
| Roll forming | Press brake | |
|---|---|---|
| Quantity | Large | Small to medium |
| Length | Unlimited | Limited by machine |
| Tooling cost | High (roller set) | Low |
| Profile changes | New rollers | Quick |
Typical products
- C and Z purlins and channels
- Racking and shelving uprights
- Door and window frames
- Roofing and wall sheets
- Electrical cable trays and strut channels
What to send
- Profile drawing with all bends and tolerances
- Material, grade, coating and thickness
- Lengths and quantity per length
- Holes or notches needed on the line
- Yearly quantity, which decides tooling payback
Need roll forming done?
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Questions
- Is roll forming worth it for small orders?
- Usually not, because each profile needs its own roller set. For small quantities, press brake bending is cheaper.
- Can holes be punched during roll forming?
- Yes, many lines punch holes and notches before or after the rollers, so parts come out ready.
- Which materials can be roll formed?
- Most sheet metals: cold rolled, galvanised, pre-painted, aluminium and stainless steel.
The figures on this page are typical values for guidance, written by Diemeco from standard engineering practice. They are not a specification: confirm grades and properties with the relevant standard or the supplier's mill test certificate, and tolerances with your workshop. Last checked 23 October 2026.