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

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

A. 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 better for small runs?

A. It depends. Press brake forming generally requires making
of more test blanks - which is 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 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 any difference in total material cost
between 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; roll forming accommodates very long parts lengths
because the material is in coil form.

Q. Which method delivers the greatest
parts accuracy?

A. Press brake forming is universally regarded as an “art,”
and varying levels of quality are a reality. Out-of-tolerance
parts are salvaged or scrapped. 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 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 roll forming, metal 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 roll forming less affected by process variables.

Q. Do roll forming and press brake forming
have similar 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. Will roll forming work for
this application?

A. With press brake forming, the part length can’t be any
longer than the width of the brake press die. 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, 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 and is 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 roll forming usually leaves less
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 has some variation. Radius bending is
one task where roll forming is virtually always a better
alternative.

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

A. A single bend is accomplished easily with roll forming
or press brake. The advantage of 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 • fax: 313.531.0480
email: sales@moheco.com

© 2007 by Moheco Products Company. 
All rights reserved.  SITEMAP
We're a contract manufacturer of roll forming products / parts,
serving contractors, distributors, and manufacturers.

ROLL FORMING
VS.
STAMPING