A very basic but important for metal fabricators is this: when should you get into roll forming? How do you justify it? In this post, we'll discuss some rules of thumb for when metal fabricators should begin looking into roll forming.
Generally, a shop that's already press braking, that their volumes have increased, is a good candidate for roll forming, as long as the parts are roll form-able. If the volume has grown enough, it's likely time to graduate over into roll forming. But what's a good number? It's definitely not 30,000 feet; usually in the several hundred thousands of feet range to be able to justify the equipment.
Roll-forming is a high volume production system. If your shop can run a part at a hundred feet a minute and the part is 10 feet long, it doesn't take long to run 300,000 feet. There are applications where you may run slower, but even if you're running 20 feet a minute, and your average part length is 5-6 feet, this is still a lot of parts. Most shops want to make sure their machines are constantly running, unless you have a specialty application, like aerospace, where the material costs matter more than anything and the client just needs the consistency that you get. In general, you should start looking at roll forming once you hit the over 300,000 feet range, and definitely if you're over a million.