Custom Roll Forming

Custom Roll Forming is the process of custom shaping strip metal by passing it through a series of specially designed rolls. With over 75 years knowledge, experience and technical expertise of cold roll forming, Metsec is ideally placed to help support our customers by offering tailored solutions to satisfy almost any requirement.

The roll forming process can not only manufacture typical shaped sections such as Channel, Angle, Boxes and Round tube but is also able to form more complex profiles required for demanding technical solutions. The ability to form complex shapes also gives the designer manufacturing options other than more traditional type processes such as press or press braking to form a product.

Metsec provide bespoke and standard metal profiles in gauges from 0.5mm up to 6mm thick, with irregularly shaped welded tubes a speciality. These tailor-made profiles can be manufactured from steel, aluminium, copper, brass, stainless steel and even pre-painted materials.

Another advantage of roll forming is that stress caused when bending materials too quickly can be avoided. From the initial roll tooling design the process undergoes a full Finite Element Analysis to ensure that the product is produced exactly to our customers design without inherent weaknesses. Overall the reduction of unwanted material stresses can be avoided by intelligent design and the gradual continuous forming process.

Through many years of experience we have designed our equipment to be innovative and adaptable. By offering further benefits to our customer such as in-line company logo embossing, printing, in-line piercing, in-line high frequency welding, saw and tool cut to length options, swaging and forming during the cut off process allows us to manufacture fully finished products without any additional secondary processing costs.

From initial concept through to final approval, here’s an outline of our custom roll forming process:


Metal strip passing through a decoiler

High quality metal strip – ranging from 0.5-6mm thick according to the customer specification – is loaded onto the decoiler and fed through the entry guide.


Metal strip being pre-pierced

The strip is fed through our pre-piercing machine where holes can be pierced as specified.

Roll Forming 1

Metal strip being fed through forming rolls

The strip is then fed through to the forming rolls, which gradually change the shape of the strip to generate the desired profile.

Roll Forming 2

Each roll performs only an incremental part of the bend

Each roll performs only an incremental part of the bend, until the desired cross-section profile is achieved.

Roll Forming 3

The profile gradually begins to take shape

Step by step, with every forming roll, the profile gradually begins to take shape, providing superb dimensional accuracy and a smooth finish.

Induction Welding 1

A closed profile approaches the induction welder

If a closed profile is required our induction welding process provides an almost flat weld seam with strength superior to the yield of the parent material. We then use eddy current testing to ensure weld integrity.

Induction Welding 2

The tube is sealed by the induction welder

The tube is sealed, generating a complete profile with a flat, almost invisible, seam and a weld strength superior to the yield of the parent material.

Flying Cut Off

The flying cut off cuts the profile into individual lengths

The profile is then fed through to our flying saw, which cuts it into individual lengths. The individual profiles are then released and stacked together, ready for final packing and dispatch or to move on for secondary operations.

For more information on Metsec Custom Roll Forming, or to find out how we can help you, please contact us:

Contact Metsec Engineering