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 a continuous bending process that shapes aluminum sheets and strips into various profiles. This method creates openings, closures, and wide deformed sections of aluminum.

In roll forming, the metal sheet or strip moves through a series of rollers. These rollers gradually bend and shape the material to meet specific dimensions. The process is efficient and allows for high production rates, making it suitable for many applications in construction, automotive, and manufacturing.

Roll forming produces long lengths of uniform profiles, which can be cut to size after shaping. This consistency makes it an excellent choice for projects that require precision and quality.

Roll-formed aluminum applications

• Aircraft airflow panels, aircraft wings
• Car doors, subway doors
• Roofing, facade, wall panels

Advantages of Aluminum Roll Forming

1. High Production Efficiency – Aluminum roll forming is a continuous process that achieves high efficiency and large-scale production. It can increase production rates by more than four times compared to stamping.
2. High Material Utilization – The roll-forming process maximizes material use and reduces waste. It saves about 15% more aluminum than the extrusion process. This efficiency means less material is wasted, making roll forming a cost-effective choice.
3. Good Surface Quality – During roll forming, the metal surface is rolled and polished multiple times. This results in a smooth and uniform finish that enhances both appearance and performance. The smooth surface of aluminum produced through this method has an appealing metallic feel.

These advantages make aluminum roll forming an excellent option for manufacturers seeking to optimize production while maintaining high quality.

Disadvantages of Aluminum Roll Forming

1. Limited Production Range – Aluminum roll forming is best for producing profiles with simple shapes and long lengths. It struggles with complex shapes and significant curvature variations, making these designs difficult or impossible to create.
2. Inability to Produce Smaller Parts – The roll-forming process works well for larger aluminum profiles, such as pipes and fittings. However, it has difficulty producing small aluminum components, which can lead to inefficiencies.

These disadvantages highlight situations where aluminum roll forming may not be the best choice, especially for projects that require intricate designs or smaller 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 inside a die. This pressure forces the aluminum to flow through the die-holes, creating the desired cross-sectional shape. It’s similar to squeezing toothpaste from a tube.

As the softened aluminum billet moves through the die, it forms various shapes and sizes of aluminum profiles. This process efficiently produces complex shapes that meet specific design needs.

Application of extruded aluminum

• Aluminum door and window frames, aluminum curtain wall
• Aluminum Deck, Aluminum Tube
• Aluminum enclosures and aluminum heat sinks

What is the Advantage of Aluminum Extrusion?

1. Better Precision: Aluminum extrusion produces products with high accuracy and tight tolerances. This precision meets the needs of various machining applications, such as aluminum heat sinks and electronic enclosures.
2. Flexibility in Production: Aluminum extrusion allows for significant flexibility. By changing dies and adjusting process parameters, manufacturers can create profiles of different shapes and sizes. For example, they can produce aluminum door and window frames or aluminum decking in one day.
3. Material Strength: Extruded aluminum profiles have superior compressive strength, hardness, and bending strength. The extrusion process improves the material’s resistance to heat treatment, making it stronger. For instance, the tensile strength of 6061 aluminum extrusion profiles in the T6 heat-treated state can exceed 310 MPa.

These advantages show why aluminum extrusion is a preferred choice for many applications. It provides precision, flexibility, and strength, making it suitable for a variety of industries.

What are the Disadvantages of Extruded Aluminum?

1. Low Production Efficiency – Conventional aluminum extrusion methods do not allow for continuous production. The extrusion speeds are slow, and productivity decreases further when making large aluminum profiles.
2. Material Waste – The aluminum extrusion process can create defects or failures in the finished products. Typically, 8-16% of the aluminum is wasted during production, which raises overall costs.

These disadvantages highlight some challenges with aluminum extrusion. While it offers benefits, manufacturers should consider these factors when deciding on this method for their projects.

Roll Formed Aluminum vs. Extruded Aluminum: How to Choose?

After reviewing the advantages and disadvantages of extruded and roll-formed aluminum, how do you choose the best option? Here are some tips to help you decide.

High Demand and Short Lead Times

Roll forming usually produces larger quantities in less time. This method is ideal for projects that need fast, high-volume production. In contrast, aluminum extrusion takes longer and suits smaller orders and complex products.

Complex Aluminum Products

If your project requires intricate designs, choose extruded aluminum. This process creates profiles in various sizes and shapes, including hollow and solid profiles, as well as complex door and window designs.

Variety of Appearances

Extruded aluminum offers a stylish finish. It comes in many options, allowing you to select smooth surfaces, textures, or specific aesthetic appeals to meet your project needs.

Lower Budget Options

Roll-formed aluminum is generally less expensive to manufacture than extruded aluminum. The extrusion process can waste 8-16% of the aluminum, which increases costs. If your budget is tight, roll-formed aluminum may be the better choice.

Making the Best Choice

With these factors in mind, you can decide between roll-formed aluminum and extruded aluminum. Each project has unique needs, so consider these points carefully.

Read more: The ultimate guide to aluminum extrusion processes & benefits

Choose what works best for you!

Hugh Aluminum is an experienced manufacturer of aluminum extrusion with 14 years in the industry. We provide services from design to production.

If you want to purchase extruded aluminum in bulk, please contact our friendly and professional team!