At voestalpine Roll Forming Corporation, we provide advanced roll forming solutions for custom shapes and complete assemblies. We manufacture custom metal roll-formed products with challenging design criteria and close tolerance specifications. Our services extend from engineering and design to tooling and manufacturing, and we also provide secondary services such as metal finishing, welding, punching, and cutting to length. For a fully integrated solution, we can also combine multiple separate shapes into a single profile.
With seven production facilities in three states, Kentucky, Pennsylvania, and Indiana, our roll forming operations feature enormous capacity. We use state-of-the-art technology to obtain tight tolerances, excellent part uniformity, and high-quality surface finishes on complex cross-sectional profiles. Almost any metal, ferrous or nonferrous, with various surface coatings, ductility, and dimensions can be roll-formed into shapes and profiles measuring up to 16” wide x 40’ long. We work with raw material from .020” to .250” thick.
As a global leader in custom roll forming, we provide engineering support at any level, from insights on design for manufacturability to full-service product development. Using the latest design software and CNC machines, we build all tooling in-house to streamline production, reduce lead times, and react quickly to specification changes. Some examples of our roll-formed products include custom angles, channels, tubes, purlins, roof rails, etc.
We operate in a lean manufacturing environment, hold ISO 9001 and AS9100D certifications and several Nadcap approvals. Markets served include aerospace, construction, material handling, ecommerce warehouse fulfillment, off-highway, office furniture, solar, and transportation. Contact us directly for more detailed information about our custom roll forming services and the various types of metal roll formed components we supply.
As a leading global resource, at voestalpine Roll Forming Corporation, we offer collaborative engineering services for custom roll-formed tubes and products. We operate an extensive engineering department to deliver an innovative solution for every application. Along with entirely custom-engineered designs, we modify our standard structures with secondary operations.
Our engineering services incorporate CAD modeling with advanced engineering analytics, rapid prototyping, tooling development, and product testing. We focus on creating parts that optimize current processes and offer benefits in terms of manufacturability and cost reduction. Our engineers carry out detailed analyses to measure performance of different designs and materials to ensure product quality and reliability. Studies include FEA, failure and fatigue analysis, thermal performance, etc.
We tap into the advantages of roll forming to engineer products that can be produced consistently to very tight tolerances and with excellent surface finishes. With roll forming, we can process materials like high-strength steels without breaking or tearing, allowing us to create strong and light components that actually require less steel than alternative forming methods like press braking or extrusion. We guide the development process from drawing to 3D printing rapid prototypes, and tooling development for pre-production models for use in trials and testing.
We have decades of experience, and our engineering services are backed up by our global resources and our expertise with roll-formed steel structures. One of our specialties is engineering strong and lightweight roll-formed tubes for roll-over protection structures (ROPS) and falling-object protection structures (FOPS) for off-highway applications. For additional information about our engineering services for custom roll-formed tubes and products or to arrange a consultation, contact us directly.
At voestalpine Roll Forming Corporation, fabricating structural steel tubes is one of our core strengths. We operate multiple fabrication plants that incorporate an impressive range of manufacturing technologies for tube fabrication, including roll forming, tube milling, 5-axis laser cutting, tube bending, free-hand and robotic welding, and CNC machining. Our tube fabrication services are backed up by an engineering team with decades of experience in structural engineering and strong capabilities in using FEA and other engineering analysis and design software.
We provide custom fabricated tubing for various applications across industry. Along with tubes for roll-over protection structures (ROPS) and falling-object protection structures (FOPS) for off-highway vehicles, we manufacture tubing for aerospace, solar energy, material handling, ecommerce warehouse fulfillment, construction, and furniture applications. We have the manufacturing capabilities and quality certifications to comply with the strictest industry standards.
We manufacture round, square, oval, and custom tube profiles with ID/OD in the 1” to 5” range. Wall thickness can be specified between .188” and 4.77,” and we supply lengths to 40’. Materials of construction include stainless steel, steel alloys, titanium, copper, aluminum, nickel alloys, and many others. With our flexibility, we produce tubes with complex designs and bend profiles, intricate laser cut features, and multi-component welded assemblies.
Working within a lean manufacturing framework, we offer ISO 9001 and AS9100D certified quality assurance, Nadcap approved laser welding, heat treating, and NDT. We accept orders of any size and implement in-line systems for roll forming and laser welding for assembling larger volumes of profiles and sections. As a company, we are customer-focused, quality-oriented, and community-minded. For more information about us or our tube fabrication capabilities, contact us directly.
As a custom roll former, we offer welding services to provide customers with a one-stop solution. Our vast welding capabilities include robotic, in-line, laser, and resistance welding technologies that we use individually or in combination to complete product designs. Our team consists of welding engineers, certified welding inspectors, certified manual welders, and professional trained robot technicians. We are certified to AWS C1.1, D1.1, D1.3, D14.3, and D17.1 standards and our laser welding services are Nadcap approved. Welding critical safety and structural assemblies is one of our strengths.
We commonly leverage in-line robotic welding technologies to assemble products such as structural racking for the material handling and ecommerce warehouse fulfillment industries. We use 3D simulations to set up systems and accelerate development and production time, and our robotic weld cells operate at fast cycle times and uphold strict weld quality standards. In addition, we can integrate process technologies like labeling and custom packing for a fully automated solution.
With our laser welding capabilities, we handle titanium welding to create durable lightweight components, such as seat tracks, frames, and channels that exceed aviation standards for performance and safety. We also combine laser, MIG, TIG, and plasma arc welding with roll forming to join intricate shapes, profiles, and sizes into finished products for the construction, off-highway, furniture, renewable energy, and transportation industries.
With our versatile welding services, we process all types of metal. Along with aluminum, copper, steel, and stainless steel, we weld copper, exotics, and alloys like Hastelloy® and Monel®. Welding critical safety structures and structural assemblies is one of our strengths. We weld low volume quantities and well as mass produced products. For more detailed information about our welding services or to make and inquiry, contact us directly.
