Extruded Aluminum

If you’re considering extruded aluminum for component parts
or assemblies, 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 extruded aluminum.  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
for these applications.  

Factors favoring extruded aluminum 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 advantage.    

The dies for extruded aluminum are less expensive to
manufacture. These dies are just a single piece of metal,
so fabrication is simplified.  Roll forming involves an intricate
die, and several passes of the material, to form the desired shape. 
So the dies needed for roll forming are more expensive than
for extruded aluminum.  

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 automobile, 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.

The dies used for roll forming 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. Extruded aluminum produces more scrap
than roll forming. 

Considering the comparative strength of a roll formed part vs.
extruded aluminum, the extruded aluminum will always have
the advantage, because there is more material involved. 

Another factor is the material compatibility of extrusions vs.
roll forming.  Roll forming is compatible with a wide 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

© 2011 by Moheco Products Company. 
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Moheco specializes in extruded aluminum parts.

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ROLL FORMING
VS.
PRESS BRAKE

ROLL FORMING
VS.
STAMPING