Roll Formed Aluminum vs Extruded Aluminum: Which is Best?
With regards to metal fabrication processes, there are two prominent processes in aluminum forming: roll forming and extruded aluminum. Both methods offer unique advantages, but understanding their characteristics can help you make better aluminum product choices.
What is aluminum roll forming?
Aluminum roll forming is by continuous roll bending method. Aluminum sheet and strip are processed into various openings, closures, and wide deformed sections of aluminum. In the process, the metal sheet or strip is continuously extruded and rubbed by a series of rollers to gradually deform and achieve the required shape and specifications.
Roll-formed aluminum applications:
- Aircraft airflow panels, aircraft wings
- Car doors, subway doors
- Roofing, facade, wall panels
Advantages of aluminum roll forming:
High production efficiency:
Aluminum roll forming is a continuous production process, which can achieve high efficiency and large-scale production. Compared with the stamping process, roll forming can increase the production efficiency by more than 4 times.
High material utilization:
In the roll forming process, the material can be fully utilized, reducing the amount of waste produced. Compared with the extruded aluminum process, roll forming can save about 15% of material. This means more aluminum will be saved by using it.
Good surface quality:
During the roll forming process, the metal surface is rolled and rubbed several times to obtain a smoother and more uniform surface quality. This helps to enhance the appearance and performance of the product. The smooth surface of the aluminum sheet manufactured by this process has a unique metallic feel.
Disadvantages of aluminum roll forming:
Limited production range:
Aluminum roll forming technology is mainly suitable for producing aluminum profiles with simple shapes and long lengths. For aluminum profiles with complex shapes and large variations in curvature, roll forming will be more difficult and may not even be possible.
Smaller products cannot be produced:
The roll forming process, on the other hand, is suitable for the production of larger aluminum profiles, such as pipes and fittings. It has a hard time accomplishing its goals when faced with the requirement of producing small aluminum parts.
What is extruded aluminum forming?
Extruded aluminum forming is a common metal processing method. It uses an extruder to apply high pressure to a billet of aluminum alloy in a die, forcing it to extrude through the die holes and form the desired cross-sectional shape . (It is similar in principle to squeezing toothpaste). The softened aluminum billet is extruded by mechanical pressure into various shapes and sizes of aluminum profiles.
belows video can help you understand what is aluminum extrusion：
Application of extruded aluminum：
- Aluminum door and window frames, aluminum curtain wall
- Aluminum Deck, Aluminum Tube
- Aluminum enclosures and aluminum heat sinks
What is aluminum extrusion advantage？
Extruded aluminum precision is better:
Aluminum extrusion produces aluminum products with better accuracy and lower tolerances. Therefore, it can meet the requirements of various precision machining. For example, aluminum heat sink, electronic aluminum shell.
Flexibility in production:
Aluminum extrusion offers greater flexibility. It can produce aluminum profiles of different shapes and sizes by changing dies and adjusting process parameters. For example, it can produce aluminum door and window frames or aluminum decking in one day.
Material Strength:
Extruded aluminum profiles have better compressive strength, hardness and bending strength. Because aluminum extrusion is compression resistant for heat treatment. This process can make aluminum metal stronger. For example, the tensile strength of 6061 aluminum extrusion profiles in T6 heat-treated state can reach more than 310MPa.
So，what are extruded aluminum disadvantages?
Production efficiency is low:
None of the conventional extrusion methods can achieve continuous production. Extrusion speeds are relatively low, and productivity is even lower when manufacturing large aluminum profiles.
The manufacturing process wastes aluminum:
Aluminum extrusion processes can result in poor finished products or extrusion failures. Typically, 8-16% of the aluminum metal is wasted, which can result in higher production costs.
Rolled Formed Aluminum vs Extruded Aluminum：How to choose
When we have found the advantages and disadvantages of extruded and roll formed aluminum. How should we choose the best one? These suggestions below can help you choose them better.
When you have high demand and short lead times
Roll forming can usually produce larger quantities in less time. This is a preferred option for projects that require fast, high-volume production. Aluminum extrusion takes longer to produce, and it’s better suited for smaller orders and complex products.
When you need complex aluminum products
Extruded aluminum would be a better solution. This is because aluminum extrusion is able to produce aluminum profiles in a variety of sizes and shapes. For example, hollow and solid profiles, complex door and window profiles.
You want aluminum products with a variety of appearances
The appearance of extruded aluminum is stylish and beautiful. It is available in a wider range of finishes. Whether you need a smooth surface, a texture or a specific aesthetic appeal, extruded aluminum can meet these needs.
Lower budget options
Roll formed aluminum is less expensive to manufacture than extruded aluminum. As we mentioned above, extruded aluminum wastes a certain amount of aluminum in the manufacturing process. This will increase the cost of manufacturing and if we have a low budget for our project, we should go for rolled aluminum.
Finally, choosing the best for your project
After the above instructions. You are better equipped to make an informed decision between coil formed aluminum and extruded aluminum. Every project has unique requirements, so weigh these considerations carefully.
Make the choice that’s best for you!
Hugh Aluminum is an aluminum extrusion manufacturer. With 14 years of manufacturing experience, we offer services from design to production.
If you want to purchase extruded aluminum in bulk? Contact us for a friendly and professional team!
