roll forming machine manufacturers

Are you working on a project that involves metal cladding installation? If so, you may have questions about the strength, durability, and corrosion resistance of the 'tracks' (or anchor system) into which the metal wall cladding system will fit. We'll try to answer some of those questions below. CHOOSING THE RIGHT MATERIAL FOR METAL CLADDING INSTALLATIONS Just like the cladding itself, the tracks have to stand up against the most inclement weather, including heavy winds and torrential rains.  This requires a strong metal that resists corrosion. Choosing the right metal for your exterior application is crucial to the long-term success of your project. So, what are your choices? Many cladding support components are made from G90 galvanized steel because of its decent corrosion resistance relative to its price. since the facade anchors won't be seen. The strength and durability of those anchors should be your focus, and G90 fits the bill.  What exactly is G90 galvanized st...

Who wants to make great roll formed parts? Not you, obviously. Optimization is so boring. You’re a trailblazer, a forward thinker -- and that means going against the grain and breaking tradition. That’s what we like to see. And to help you out in your innovative efforts, we've put together some tips to design the crappiest roll formed part you’ve ever seen. (This information is based on over 115 years of experience. It’s guaranteed to ruin your roll formed parts. Good stuff.) ROLL FORMED PARTS: 5 SURE-FIRE WAYS TO RUIN YOUR DESIGN There are many ways to absolutely botch your roll formed parts. And the majority of the time, these decisions are made during the design process. So, if your goal is to be crowned as the king of poor roll forming design, consider these 5 tips: Produce super-tight tolerances Make your component out of space metal Punch holes directly on bends Request near-useless legs Aim for tight corners 1.  Produce Super Tight Tolerances That’s right. Get those babies n...

At Dahlstrom, we fabricate only the highest quality metal mouldings to help you create a sleek, elegant atmosphere for any room. We pride ourselves on the rich history of our products. Our oldest designs originate from the industrial era - America’s Big Bang. Even better, Dahlstrom still uses the same tools and manufacturing processes that have been in place since our inception in the early 1900’s. In addition to their historic authenticity, learn why designers choose metal mouldings over wood. Got all that? Good. Now, let’s get started on the basics. TYPES OF MOULDINGS Baseboards Baseboards create a visual break from the horizontal floor to the vertical wall. They perfectly accent the floor design, protect the edges of the room, and create an eye-catching boundary that separates the building’s directional planes. The height of your baseboards is the largest factor in determining their aesthetic appeal: short baseboards can look cheap and unassuming, while taller baseboards lend natura...

Choosing the right aesthetic for your architectural project is more complex than it may seem. There are many metals to choose from, and many types of finishes available. Each finish provides its own unique aesthetic, and the finished effect will shift depending on the richness, lighting, and color of the surrounding environment. TYPES OF METALS Copper Copper is a natural, pure red metal, one of the first metals ever worked by human hands. Copper_knife,_spearpoints,_awls,_and_spud,_Late_Archaic_period,_Wisconsin,_3000_BC-1000_BC_-_Wisconsin_Historical_Museum_-_DSC03436 It’s extremely durable and uniquely beautiful. For architectural purposes, the most enticing characteristic of copper is the way it oxidizes and ages. No other metal turns as brilliantly or naturally seafoam green over the years, with no help from a human hand (though there are ways to synthetically age metals to produce this effect). The exact hue it turns will depend on the climate; humid climates produce the familiar g...

Copper. Brass. Bronze. Reminiscent of the pharaohs in Egypt, the temples of Sri Lanka, the Gothic cathedrals of the East. These are the red metals - luxury metals. The red metals embody luxury in architecture. They’ve housed the greatest kings and queens for millennia. They’ve formed the greatest works of art. And they’re still standing for us to see today. These metals are a given for any upscale designer who wants to build a high-class reputation. Because of their price point, they’re perfect for clients who are willing to pay for a higher quality design. They’re also quite unusual because of their cost - ensuring that your design will make an immediate impact on any admirer. Here are a few ways to scale up your design with luxury metals. LUXURY METALS: APPLICATIONS, USES, AND A BONUS Cladding It’s a rare client that’s willing to pay for solid copper, brass, or bronze elements. A more realistic approach is to clad the item in the desired metal. Cladding is typically applied to walls,...

When you think about supply chain risk mitigation, what are the first things that come to mind? For us, the usual suspects are: Controlled costs On-time delivery Freight utilization (proximity and load efficiency) Quality control Correctly designed packaging These things are Supply Chain Management 101. Standard operating practices. But if you really want to protect your supply, your vendor needs to go above and beyond 101 SOPs. THE MOST IMPORTANT ASPECT OF SUPPLY CHAIN RISK MITIGATION Long-term, dynamic supply chain management can’t coast on the basics. It requires advanced planning, optimization, and reviews. It requires regular, recurring, formal communication about the entire supply system. Communication on system status keeps you in the know and your vendor on track. It helps you both identify opportunities and mitigate risks before they arise. Surprises can be costly! Not every vendor will have the expertise or desire to go the distance. A high-quality vendor will know how to tra...

The oceanfront is a beautiful but expensive place to live. And as it turns out, it’s also one of the most difficult places to use metal in outdoor architecture.  The salt and moisture of the seaside makes long-lasting construction a challenge. The majority of coastal buildings need maintenance every few decades or, depending on the metal used in their construction, they may need to be completely replaced. And while most metals are resistant to corrosion, they are not immune. Those that are immune to corrosion are typically luxury metals that carry big price tags. As you move further inland, all metals survive longer thanks to lower levels of salt in the environment. It won’t save them from the rain and weather, but they stand a better chance. No matter where you build, your architecture will be exposed to wind, rain, and possibly salt and other elements. Deciding on the best metals for exterior applications can be the difference between a long-lasting tribute to your skill and an u...

When it comes to roll forming cost, if price is the battle, total cost of ownership or -- TCO -- is the war. TCO is an analysis of the complete life cycle of your purchase. The number includes every phase of ownership. Parts with a lower TCO are better in the long run when it comes to roll forming cost -- even if the initial purchase price is higher. Are you getting the most out of your metal manufacturer? Keep reading -- and check out this TCO calculator or one of the many others available online. DEFINING YOUR TCO FOR ROLL FORMING COST TCO highlights the difference between purchase price and long-term cost. It consists of Equipment and material costs: These include the cost of equipment, but also installation and any necessary upgrades. Personnel costs: These include in-house staff and any outsourced help. Ongoing employee training, project management, and resources for rejects/rework also factor in here. Operating costs: These include inventory, utility costs, waste disposal, and mo...

To many, roll forming metal seems like a niche process, used only in limited situations to form steel profiles. Consequently, the process itself is not well-understood by the public, which means misconceptions develop and persist. We're here to clear the air and address those misconceptions directly. DISPELLING THE 4 MOST COMMON MYTHS OF ROLL FORMING METAL 1.  Roll forming tools are too expensive. Tooling for any kind of metal fabrication can be costly. If you buy smart, roll forming tools are no more expensive than any other type of tooling. Here are a few ways to mitigate high tooling costs: If your manufacturer participates in part design, they may be able to save you money on tooling by optimizing the part for roll forming processes. Payments can be amortized over a period of time to avoid high up-front costs. Your manufacturer can discount or rebate the cost of tooling, in exchange for a commitment to buy a certain amount of parts over time. In the case of Dahlstrom Roll Form,...

Metal is in style. Each metal creates a different aesthetic, meshes well with other materials, and is highly functional for a variety of applications. Metal is striking, enduring, and practical - just like your design. Your design is unique, and deserves to be executed well. That’s why you need an expert partner. You need someone who has experience in crafting and installing metal architectural components, which they use to actualize your design to its fullest potential. Partnering with someone like this can add value for you and your customer. Here are three things your “metal expert” partner  should have to make your architectural design a smashing success. 3 TRAITS OF AN AWESOME METAL FABRICATION PARTNER 1.  Competency While there are many metal fabrication services available, not all of them will have experience in architectural design. In fact, most probably don’t. Metal fabrication is more often used for OEM and contract purposes. OEM designs rely on functionality first....

Charles P. Dahlstrom was an innovator who helped usher in a new era of architectural safety. As the industrial revolution seized America, more and more fires broke out due to the country’s lack of experience with its new technologies. Buildings were mainly constructed of wood and other flammable materials, with no legitimate means of slowing a fire once it started. It  was only a matter of time before someone stepped up with a solution. That someone was Charles P. Dahlstrom. You see, in 1904 Mr. Dahlstrom invented and introduced the world’s first fireproof door. Anticipating a large demand for his new product, Charles launched the Dahlstrom Metallic Door Company. He then aimed to corner the budding skyscraper industry by applying his fireproof technology to elevator entrances. Finally, to round out the Dahlstrom® product line, Charles created a series of decorative metal mouldings that would complement the elegant doors his company was already producing. All of these moves proved t...

Metal is in style. Each metal creates a different aesthetic, meshes well with other materials, and is highly functional for a variety of applications. Metal is striking, enduring, and practical - just like your design. Your design is unique, and deserves to be executed well. That’s why you need an expert partner. You need someone who has experience in crafting and installing metal architectural components, which they use to actualize your design to its fullest potential. Partnering with someone like this can add value for you and your customer. Here are three things your “metal expert” partner  should have to make your architectural design a smashing success. 3 TRAITS OF AN AWESOME METAL FABRICATION PARTNER 1.  Competency While there are many metal fabrication services available, not all of them will have experience in architectural design. In fact, most probably don’t. Metal fabrication is more often used for OEM and contract purposes. OEM designs rely on functionality first....

U.S. manufacturing has had its share of bad turns over the last 50 years, with entire industries being outsourced to other parts of the world. Not good news for roll forming companies. Starting with products like clothing and electronics, we gradually saw large corporations move their production overseas or to South America to take advantage of cheaper labor and less regulation. Into the 1970s the trend continued with auto parts, furniture, toys, shoes and a host of others. Fast forward to today, and we may be seeing a more influential recognition of the value U.S. manufacturing offers: Rapid response of supply in close proximity to the largest group of consumers in the world The lowest energy costs on the world Highly advanced technology and automation A fairly stable political and market environment But as a manufacturer anywhere, what if you could outsource just one component of your finished product to a local supplier and increase your shippable units by 20% to 50%? How could this...

The hydraulic press has been around since 1795 (invented by the same guy who later created the flush toilet). This miracle machinery facilitates a clean, repeatable look for a product line. It's one of man's great industrial creations. Man also likes to destroy, though. One of the internet's more amusing trends of the last few years has been hydraulic press videos. Press operators are posting hilarious clips online of food and other consumer products being slowly crushed to death by a hydraulic press. You'll find it's just as amusing as it sounds. Keep scrolling for the proof. WHAT EXACTLY IS A HYDRAULIC PRESS? For the uninitiated: A hydraulic press is a machine that has a bed or plate on which the operator places your metal of choice. The press uses a cylinder to generate the compressive force needed to crush, mold, or straighten that metal. Common uses for hydraulic presses include: Metal forming Moulding Punching (not your brother) Deep drawing Much more Oh, and ...

You may have noticed a few differences on our website lately. To recognize the growth of our business on both sides -- OEM roll forming and decorative metal trim -- we have adjusted the website's structure to make navigation easier for customers. Here are a few things about the split that you should know: BEST OF BOTH WORLDS FOR ROLL FORMING AND DECORATIVE METAL TRIM The Format Our customers consist of two types. There are those who specify OEM components for assemblies and those who seek our famous branded decorative accents for a design composition. We’ve split the website homepage to reflect your differing needs. Open door #1, and you’ll see everything you need to know about roll forming for OEM projects. Choose door #2, and we’ll tell (and show!) you about metal mouldings’ uses in architecture. Of course, we understand your needs may overlap. Maybe you’re an architectural OEM, i.e. someone who makes doors and wants an architectural look on a fabricated product. You’ll find usef...

When you invest in metal materials, you expect them to last. But it’s a mistake to assume metal is immune to degradation from environmental and other factors. Corrosion can wreak havoc on the structural integrity and aesthetics of your parts. That’s why it’s important to know the factors of corrosion -- where it occurs most and what promotes it. Armed with this knowledge, you can account for corrosion when planning your next project. FACTORS OF CORROSION: WHAT PROMOTES IT & WHERE TO FIND IT 1. Weldingfactors of corrosion chrome bumper Welding is the best and most popular way to permanently attach two pieces of metal. But it also creates an environment where corrosion can set up shop and go wild. Every weld creates stress -- we mean in the metal, not the welder. Stress disrupts the structure of metal in ways that allow corrosion to occur. You can see examples of welds leading to corrosion in old chrome bumpers. They always rust where the deepest part of the draw is. Fortunately, you...

As with all manufacturing processes, the way you design your component impacts your overall costs, lead times, and quality consistency. Follow these roll forming design tips to avoid the common pitfalls of custom tooling and forming. Some components require difficult or non-standard manufacturing work, so you may not be able to follow all of these rules. However, by removing as many unnecessary hurdles as possible, you can make your part more affordable while maintaining design integrity. AVOID THESE 8 ROLL FORMING DESIGN OOPS-ES Roll form design can go off the tracks quickly if you make one or more of these eight mistakes: 90° sidewalls Small bend radii Extremely short legs Wide, sweeping bend radii Blind corners Narrow openings Deep, narrow sections Wide shapes & forming work on one edge While each one of this can be a problem, there's fortunately also a solution for each. 1.  90° Sidewalls The Problem: These require additional roll passes, which increase roll wear and contri...

There are plenty of other metals (besides steel) that are used for roll forming. Some of the most commonly used metals include: Aluminum Coated carbon steels Copper Bronze Brass Pre-painted coil steels Perforated metals A great engineering project always starts with the right metals -- so it’s wise to educate yourself on the pros and cons of each. Get it wrong, and you’re left with a needlessly expensive or low-quality product. It’s crucial to start your vendor on the right path instead! Let’s talk about the most important metals, then break them down into easy-to-follow categories of characteristics. (Don’t forget to scroll to the blue button below to download a full-sized PDF of all the key metals!) WHAT WE’LL COVER: ROLL FORMED STEEL & MUCH MORE Here are the metals we’ll cover in this chart: 1018 cold rolled steel Hot dipped G60 galvanized steel Hot dipped G90 galvanized steel A40 galvannealed steel A60 galvannealed steel 304 stainless steel 316 stainless steel 430 stainless ste...

There’s nothing new or mysterious about “just-in-time” or JIT manufacturing. The idea has been around since the 1970s, and all it means is that you receive what you need, just when you need it -- hence the popular term just-in-time delivery. Yet, when it first came into practice, it shook up metal forming. Why? Let's answer the question from the specific point of view of working with a roll forming manufacturer HOW DOES JIT MANUFACTURING WORK? Good question. Before answering, it should be said that, when everything that goes into supply system management -- including elements of JIT manufacturing -- is looked at together, it’s not so simple. Now, to answer the question of why JIT shook up manufacturing: On the manufacturer’s side, JIT cut inventory drastically. No longer did raw materials or finished roll formed metal sit around and pile up, stealing valuable space and representing little but expense. The stuff had to be paid for, whether used in a week or 10 years or never. And, o...

Roll Form has agreed to purchase DC Rollform, a Falconer, N.Y.-based roll forming manufacturer. In addition, Dahlstrom will purchase DC’s 130,000 sq. ft. building. The consolidation and move to the new building is scheduled to be complete by Q3 of 2020. By putting inventory buffers in place and planning carefully, we expect no disruption to any of our customer-supply programs. “We look forward to the opportunities that lie ahead by growing our business with the merged talents of our employees, and the combined capabilities of our equipment,” says Dahlstrom owner Robert White. SAME ROLL FORMING MANUFACTURER, MORE CAPABILITIES To that end, the DC Rollform building includes full liquid and powder coating equipment. This feature will immediately eliminate the need to outsource powder coating services, streamlining our customers’ supply chains. Some of the building’s machines will remain in use, increasing our capacity options for several custom roll form components we already produce. Furt...

Roll form parts are complicated. And the roll forming process is equally complicated. So, the quickest way to explain roll forming to a newcomer is to provide real-world examples.  Here are seven places you might not realize are ripe for roll forming applications. 7 ROLL FORMING APPLICATIONS IN DISGUISE Roll formed products are all around you. Just look at the buildings and infrastructure you pass by every day: Power distribution components Warehouse & data storage Commercial food storage Solar Trains Trailers & trucks Guard rails & sign posts 1. In the Power Supply For data centers, commercial retail, and higher-ed buildings, the power distribution system is absolutely vital infrastructure. These systems are highly proprietary and implemented by thousands of feet per project. Consequently, custom roll formed parts are critical in both current-carrying and non-current-carrying equipment. Copper busbars & conductors (current-carrying) Cable trays & wire raceways ...