Sika custom profiles cold formed with precision

Custom cold roll forming

The roll forming process for custom metal profiles

Custom roll forming of steel and aluminium profiles

Sika manufactures custom metal profiles by custom roll forming, a continuous and automated process that turns metal coils into high-precision roll formed profiles. Our integrated roll forming lines ensure consistent quality, efficiency and controlled costs, even on complex geometries.

The strip is gradually shaped at room temperature by a series of contoured rollers until the required section is reached. We produce roll formed steel and aluminium profiles to the customer’s drawing, with punching, welding and cutting integrated in line.

Our capabilities

Strip thickness:

From 0.4 mm to 4 mm

Strip width:

Up to 550 mm

Profile length:

From 200 mm to 1300 mm

How a cold roll forming line works

The process begins with the uncoiler, which continuously feeds the sheet metal from the coil, ensuring a steady flow for cold-formed profile production.

Before forming, the sheet is processed with a punching machine or press to create holes, slots, notches, or embossing, preparing it for customized cold roll forming.

At the heart of the process, the roll forming machine uses pairs of shaped rollers to progressively deform the sheet metal into precise sections that match the custom profile design.

Welding

High-frequency welding is used to join profiles for strong, precise connections ideal for closed sections.

After forming, these tools refine the profile, correct imperfections, and define specific curvatures or angles.

Cutting

Before advancing to the next stations, the cutting system trims the metal to predefined lengths, ensuring each cold-formed profile is perfectly dimensioned.

Cold roll forming of custom metal profiles

Finally, the finished profiles are separated into cut-to-length pieces by the unloading unit, completing the process and preparing them for further processing or shipping.

Capabilities and materials

We roll form strip from 0.4 to 4 mm thick and up to 550 mm wide, in lengths from 200 to 1300 mm. Within these limits we produce open, closed and shaped sections to the customer’s drawing, with holes, slots and joints integrated in line. The continuous process is ideal for repeat production, with consistent dimensional accuracy batch after batch.

We roll form carbon and pickled steel, galvanized steel, stainless steel, corten steel, aluminium and copper. Discover our cold roll forming technologies, or read our guide: what is cold roll forming.

The advantages of cold roll forming

Cold roll forming is the ideal solution for durable profiles produced in high volumes with a consistent section. Roll formed profiles are used in many sectors: construction, automotive, agriculture, furniture, energy and industry.

Frequently asked questions

What is the difference between roll forming and extrusion?

Extrusion pushes the metal, usually aluminium, through a die. Roll forming bends a metal strip through a series of rollers: it works both steel and aluminium, keeps a constant wall thickness and suits large series, with punching and welding integrated in line.

What thicknesses and sizes can you roll form?

We roll form strip from 0.4 to 4 mm thick and up to 550 mm wide, with profile lengths from 200 to 1300 mm.

Do you offer custom roll forming to drawing?

Yes. We produce open, closed and shaped sections to the customer’s drawing, supplied punched, slotted or welded in line, in carbon, galvanized, stainless and corten steel, aluminium and copper.

Profile with Sika

With SIKA, cold roll forming becomes synonymous with innovation and reliability, delivering solutions that transform simple metal coils into high-performance components ready to meet the most ambitious project challenges.

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Explore other processes

Cold roll forming is combined with the other processes of our production cycle: stamping, punching, bending, calendering and welding. One supplier for the complete part.

Custom cold roll forming