How an American Roll Former Can Help Improve Your Part Design

Roll forming part design can uncover ways to reduce material, add features, and rethink how a component is made. An experienced roll former may see possibilities that are easy to miss when using another process.

Many manufacturers naturally think about laser cutting, press brakes, or stamping when designing a metal part. However, a roll former looks at that same component differently.

That different perspective can create opportunities.

Scott McMeekan and Thomas McMeekan of Ferret, Inc. discussed how roll forming knowledge can influence part design. In some cases, Ferret can identify design changes that affect material use or secondary operations.

The opportunity starts by looking beyond the drawing and asking another question:

What could this part look like if we designed it with roll forming in mind?

How Can a Roll Former Look at Your Part Differently?

An experienced roll former can look at a component through a different manufacturing lens. That perspective may reveal options a designer did not originally consider.

Scott says many manufacturers think about other processes first.

Laser cutting may come to mind. A press brake could be another option. Stamping may also enter the discussion.

Ferret brings a different perspective because its team understands what roll forming can accomplish.

That knowledge can change how people view future parts.

Thomas describes the shift:

“You kind of start, you flip. You don't see laser press brake or press breaking in general. You kind of start thinking about roll forming.”

That mindset is valuable for roll forming part design.

Once manufacturers understand the process, they may begin looking at components differently. Instead of automatically selecting a familiar process, they can ask whether roll forming offers another path.

The goal is not to replace every manufacturing process with roll forming. Rather, it is to recognize opportunities where roll forming may fit the part.

Can Roll Forming Part Design Reduce Material?

Roll forming part design may create opportunities to reduce material while still producing the component the customer needs. Even a design change can affect the amount of material used.

Scott says Ferret sees design improvement opportunities “all the time.”

For example, the team may look at a part and identify a way to change its shape or add a feature. That adjustment can sometimes reduce material.

Scott explains that Ferret may find an opportunity to take out “10 or 15% material weight and therefore cost.”

That is a meaningful design conversation.

Instead of accepting the original component as the only option, Ferret can use its roll forming engineering experience to explore another approach.

The potential benefit goes beyond material alone.

A successful change can also show the customer what else may be possible with roll forming. One design idea can lead to another component or application.

Therefore, manufacturers should not view a drawing as untouchable when asking a roll former for input.

Sometimes a small change in the design can create a different manufacturing opportunity.

Can Features Be Added During Roll Forming?

Some part features may be possible in-line rather than through a separate operation. A roll former can help identify those opportunities during a design review.

This is another area where process knowledge matters.

A customer may assume that a certain feature requires a secondary step. However, Ferret may see an opportunity to incorporate that feature during the roll forming process.

Scott says customers do not always realize what can happen in-line.

That creates an opportunity to rethink the part and the process together.

Thomas's comments also highlight why experience matters. As manufacturers become more familiar with roll forming, they begin seeing applications they may not have considered before.

That shift can create an “aha” moment.

The customer no longer looks only at the current part. Instead, the team starts thinking about other components that could benefit from the same approach.

For that reason, a roll former can contribute more than production capacity.

The team can provide manufacturing insight that helps customers think differently about the parts they design.

Look at Part Design Through a Roll Forming Lens

Roll forming part design is about considering what the process can contribute before assuming the original design is the only option. An experienced roll former can help identify material, feature, and process opportunities.

Ferret sees these opportunities often.

A customer may begin with a part designed around laser cutting, a press brake, or stamping. However, looking at that component through a roll forming lens can create another set of possibilities.

That could include reducing material. Another opportunity may involve adding a feature in-line. In other cases, the biggest benefit may simply be discovering a different way to manufacture the part.

Thomas describes the mindset shift well. Once you understand roll forming, you begin thinking about roll forming.

So, when reviewing your next component, consider asking:

Could this part be designed differently if a roll former looked at it first?

That question could open the door to a new design approach.