Aluminum Extrusions

If you’re considering aluminum extrusions, here are a few insights
that can help you determine whether another technology, such as
roll forming, could deliver better results.

Storm windows and window channels are common applications
for aluminum extrusions.  The material is thicker than what could
do the job if the parts were roll formed - and often unnecessarily so.
Roll forming is a much leaner, more “material-efficient” process.  

Factors favoring aluminum extrusions include the flexibility to
add slots and openings in the part.  This is not practical with
roll formed parts, except as a post-process step, but when
slots are not needed, roll forming usually has the edge.    

The dies for aluminum extrusions are less costly to make. 
These dies are just a single piece of metal, so fabrication is
straightforward.  Roll forming involves an intricate die, and
multiple passes of the material, in order to form the desired
shape.  So the dies needed for roll forming are more expensive
than for aluminum extrusions.  

The costlier roll form tooling is more cost effective where volumes
are high (thousands of feet or parts). This is one reason most of
the painted or chrome trim on your car, for example, is roll formed.
Many other covered parts of your car are also roll formed, because
of the many thousands of pieces required each year.

Roll forming dies produce more ft. per hour, and also more parts
per pound of raw material. These are two significant considerations
when quantities are high, and when material costs are volatile and
rising. Aluminum extrusions produce more scrap than roll forming. 

Looking at comparative strength of a roll formed part vs. aluminum
extrusions, the aluminum extrusions will always have the edge -
for the simple reason that there is more material involved. 

Another factor is the material compatibility of extrusions vs.
roll forming.  Roll forming is compatible with a broad range on
materials, not just aluminum.  Extrusions are limited to aluminum
and sometimes brass.   Also, roll forming is compatible
with many prepainted, and preplated metals, so color or
performance properties such as corrosion resistance can
be imparted, before the material is formed.

MOHECO PRODUCTS COMPANY
26835 West Seven Mile Road
Redford, Michigan 48240
888.814.3721 • 313.531.5630
fax: 313.531.0480
email: sales@moheco.com

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We're a contract manufacturer of aluminum extrusion parts
serving contractors, distributors, and manufacturers.

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ROLL FORMING
VS.
PRESS BRAKE

ROLL FORMING
VS.
STAMPING