Metal Roll Forming vs.
Press Brake Forming
“Which is Best for Your Project?”

Q. Is the per-piece cost generally less with
metal roll forming, or press brake forming?

A. Metal roll forming -- if there is a large quantity of parts to be
made. The tooling cost is usually more for the roll formed
shape but is spread over a larger quantity of parts, making
the per piece tooling cost less. If it is a short run and the
shape is compatible for forming on a press brake, it is less
costly to use a press brake.

Q. So press brake is always preferable
for small runs?

A. It depends. Press brake forming generally requires more
test blanks – scrap – and if the part is complex and precisely cut,
and is made from a costly material, the expense of that scrap
may tip the balance toward metal roll forming for a different
reason. Many times the shape of the part is too
intricate to do on a press brake.

Q. Is there a difference in material cost
between metal roll forming and press brake?

A. The cost of the material is generally higher for press brake
forming because material has to be slit and sheeted-cut-to-
length; metal roll forming accommodates very long parts lengths
because the material is coiled.

Q. Which method produces the highest
parts accuracy?

A. Press brake forming is regarded as an “art,” and varying
levels of quality are a reality. Out-of-tolerance parts are salvaged
or scrapped. Metal roll forming produces higher accuracy, and a
much lower percentage of out-of-tolerance parts.

Q. Why does press brake forming produce
less accuracy in parts than metal roll forming?

A. The bend angles attempted with press brake forming are
dependent on the specific material, its springback properties,
and the friction between the die and the blank during forming.
In metal roll forming, the material is progressively bent, and
it’s in contact with the forming dies for a longer time. The shape
is reinforced by this lengthened contact, virtually eliminating
springback and making metal roll forming less affected by
process variables.

Q. Do roll forming and press brake forming
have the same set-up times?

A. No – the set-up for press brake is usually less than for
roll forming but the production rate piece-per-hour is much
higher for roll forming. The reason for this is that each piece
does not have to be handled individually.

Q. I have a 90 degree angle requirement on a
31’ part. We tried press brake forming; the dies
marked the part – and we had to split the part
in three sections. Is metal roll forming a good
option for this application?

A. With press brake forming, the part length can’t be any
longer than the width of the brake press die. Metal roll forming
can do the full 31’ length – and will not mark the part.

Q. Does either method offer an advantage in
reducing the number of production steps?

A. Depending on the shape of the part, metal roll forming can be
done in one operation where using a press brake can require
more than one hit. Also, depending on the part, holes and
cut-outs can be done with an inline pre-notch or the cut-off
operation, and that will reduce the number of operations
needed. This can be very significant in reducing cost and
overall production time.

Q. What about precoated or plated material?
Does either method accommodate this?

A. Both operations can be done on pre-plated or coated
material, although metal roll forming usually leaves
fewer and less visible marks on the part.

Q. Why is radius bending such a difficult
application for press brakes?

A. One reason is the metal’s springback may not be
consistent from one sheet to another. Springback is more
of an issue for metals with higher tensile strengths. And the
problem is exacerbated if the gauge or temper on long
sheets of material varies. Radius bending is one task where
metal roll forming is virtually always a better alternative.

Q. Does the number of bends help determine
whether metal roll forming or press brake forming
is the better choice?

A. A single bend is accomplished easily with roll forming
or press brake. The advantage of metal roll forming is that it
can produce multiple precision bends over thousands of feet
of material, quickly and very efficiently.

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

© 2010 by Moheco Products Company. 
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made by metal roll forming.

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