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Roll forming for automotive industry

Roll forming is a cold-forming process particularly well suited for producing long, profiled components in high-strength steels. The process uses sequential deformation in many small steps, allowing the material to be formed with high dimensional accuracy even at very high strength levels without introducing critical deformation zones or cracks.

Because the forming takes place cold, the material’s mechanical properties are retained, and in some cases the profiles are further strengthened through work hardening.

Höghållfasta material

Hög- och ultrahöghållfasta stål (UHS, UHSS) och Advanced High Strength Steel (AHSS) blir allt viktigare vid rullformning eftersom de ger möjlighet att använda betydligt tunnare utgångsmaterial. Den färdiga produkten blir därmed lättare trots oförändrade hållfasthetsegenskaper. Användningen av höghållfasta material innebär också en minskad miljöbelastning genom att den använda material mängden minimeras.

Material

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Material

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Material

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Material,  sustainability

The roll-forming process is compatible with several categories of modern steels with reduced climate impact, such as:

  • Fossil-free steels or other steels with low CO₂ impact 
  • Recycled steels
  • High-strength steels

The process requires significantly less energy compared to hot forming and produces minimal material waste, further reducing the total environmental footprint of the components.

 

Process advantages

  • Continuous production with high repeatability and lower variation than discontinuous methods.
  • Tight tolerances along the full profile length, improving fit and reducing fixture dependency during assembly.
  • Integrated operations such as punching, deburring, and forming in the same line to streamline production.
  • Ideal for long structural components, including frame rails, side members, sill profiles, and reinforcement sections.
  • High material efficiency due to low scrap rates and optimized coil utilization.

 

Summary

Roll forming is a high-performance and resource-efficient manufacturing method that combines:

  • High strength
  • Low weight
  • Excellent dimensional stability
  • Reduced climate impact

This makes the technology particularly attractive for the automotive industry’s transition toward more energy-efficient and climate-optimized vehicle structures.

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