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Alternative to press braking, folding/die bending

There are various production methods for making steel or aluminium profiles. The most common are extrusion, roll forming / cold rolling, press braking, folding / die bending. Press braking is done using a press that pushes or bends a sheet of metal into the desired shape.

Advantages of press braking

This sheet metal processing technique is popular because it offers a number of advantages. Since it takes little time to set up the production process, the process is flexible. It is also easy to make changes to the product or perform additional processing steps, such as punching. The total costs (tooling and products) can also be kept relatively low when producing small quantities.

Drawbacks of press braking

However, there are also a number of drawbacks to this production method. Besides the fact that metal can be scratched during press braking (which is more important to some than others), there are other major drawbacks:

  • Complex profile shapes are not possible
  • Variations in profile cross-section tolerances
  • Maximum product length is limited by length of the press brake
  • For larger volumes, other production technologies are more cost-effective

If you are looking for an alternative to press braking, folding and/or die bending, roll forming can be an extremely attractive option. Watch the video from Hadley Europe (formerly Overeem) below and read more about roll forming.

An example of another interesting processing method is roll forming. We explain exactly what roll forming is below.

Roll forming

An important aspect in which roll forming differs from press braking, folding/die bending is that the metal, which is supplied in coil form, passes through a number of ‘processing stations’. In contrast to press braking, this creates a continuous process. This continuous process leads to a kind of ‘production line,’ to which additional processing steps can be added. Some examples are perforating, cutting to length, stamping, welding and bending.

Roll forming also has other advantages. One of these is that large series can be produced with high accuracy and a consistent cross-section. All this is achieved in a short period of time.

Roll forming at Hadley (formerly Overeem)

Hadley Group has a lot of experience with roll forming. At Hadley Group, we believe that in many cases roll forming is a better production method than press braking, as it has many advantages. Hadley Group also distinguishes itself from other roll forming producers in a number of ways. One of these is the ability to produce complex thin-walled profiles. This includes applications involving pre-painted or coated materials as well as polished stainless steel with protective film. Hadley Group can also carry out custom processing steps ‘inline’. With years of knowledge, experience and investment in innovation, Hadley Group has the ability to take highly complex requirements and requests and turn them into suitable solutions for the customer.

Hadley Group: roll forming at the highest level, throughout the world.

An important cornerstone for the Hadley Group is to be able to guarantee quality and accuracy while achieving short design and production times.

Over the years, this has enabled us to offer a number of USPs, making roll forming an ideal alternative to aluminium extrusion, press braking, folding, and die bending:

  • Tolerances from ±0.05 mm
  • Wide range of geometric possibilities
  • Material thicknesses from 0.3 mm to 8 mm and up to 1.3 m wide
  • Suitable for ferrous, non-ferrous, stainless steel, and other malleable metals
  • SPC and process capacity analysis
  • Inline functions, such as perforating, embossing, bending, and cutting to length
  • Inline welding, which makes closed forms possible

We employ all these techniques for various markets, including the automotive, construction, industrial, and agricultural sectors. We serve these markets worldwide, with locations in the Netherlands, the United Kingdom, Thailand, the United Arab Emirates, and the United States. No matter where you are in the world, you can contact us for a suitable alternative to press braking, folding / die bending.

Would you like more information or do you have questions?

Would you like to learn more about how roll forming can be an alternative to press braking, folding / die bending, or do you have technical questions? Then contact us here. We will be happy to answer all your questions and discuss the possibilities for the use of roll forming for your organization.