A Symbol of Quality & Dependability in Roll Forming

Rolling Forming Capability

Roll Forming Inline Midline Presses
Roll Forming Inline Midline Presses

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Johnson Brothers Roll Forming is proud to offer high quality custom roll forming services for customers in a range of industries, featuring state of the art inline press punching equipment. Our ISO 9002 compliant fabrication methods including inline press fabrication: insertions, swedging, punching, deburring, pointed tube ends, slotting, inline miters and close tolerance cut to length. We also produce expert quality low tolerance miniature parts, and offer some flat and shaped wire forming techniques including straightening, skiving, edge rolling, cut-to-length, and ring forming inline and as an option pre-edge rolled stock. At Johnson Brothers we have over six decades experience in tubing production, including the versatile lock seam tubing, which we run faster than our competition and open seam. Sizes of roll formed components can be in up to 36' in length, and .187" to 20" in width, with thicknesses of .005" to .188", formed from a number of material options including steel, special alloys, stainless steel, aluminum, brass, copper, bronze, Inconel, titanium, wire cloth, martensite, cor-ten, high yield and high strength, Clad Metals, Flat and Shaped Wire among others. We are recognized for our advanced production abilities as non-ferrous materials specialists.

On-site machinery features press capacity from 5 to 100 tons, and spindle diameters from 1" to 2.5". On smaller, thinner parts we can maintain tight tolerances of 0.005" during production, with capabilities to meet 0.002" and larger parts and thicker materials wider tolerance ranges. Inline fabricating tolerances can be narrow on inline post punch or wider using inline pre-punching. Available finishes including pre-galvanized, pre-painted, pre-anodized, pre-plated, pre-polished, pre-perforated, pre-lacquered, pre-laminated vinyl, clad, pre-embossed, and strippable PVC over many. Our advanced production knowledge allows for attention to the specialized design aspects of the roll forming process such as end flare, while still providing high volume fabrication abilities and quick turnaround times. For more information about the custom roll forming services offered at Johnson Brothers, as well as our menu of value added secondary services please see the table below or contact us directly.

To see more of our products please browse our product catalog.

Rolling Forming Features

Fabrication Method
Roll Forming
Miniature Parts Roll Forming
Inline and Secondary Press Fabrication
Inline & Secondary Slots, Holes, Shear Forms, etc.
Inline & Secondary Cut to length
Inline Ring Bending
Inline & Secondary End Fabrications
Inline & Secondary Materials Insertion
Inline & Secondary Double Sided Tape Applicating
Inline & Secondary tube Swedging
Inline & Secondary tube End Pointing
Inline & Secondary Flattened and Bent tube ends
Inline Scoring
Inline Grooving
Inline coil edge deburring
Secondary end deburring
Burr Flattening by rolling on Prepunch Fabricating
Flat and Shaped Wire Work
Straightening
Skiving
Edge Rolling
Cut-to-Length
Light Extruding
Ring Forming
Press Capacity
5 to 100 tons
Equipment
Inline Pre-Notch Presses
Inline Midline Presses
Inline Cutoff Presses & Secondary Cutoff Presses
Inline Ring Cutoff & Secondary Ring Cutoff Presses
Inline Straightener Units
Inline Sweep Units
Secondary Fabricating Presses
Secondary Air and Hydraulic Fabricating Units
Die Accelerators
Die Boosts
Weak Part Inline Cutoff Assists
Form
Coil
Sheet
Materials
Steel
Stainless Steel
Aluminum
Brass
Copper
Bronze
Inconel
Galvanized
Titanium
Special Alloys
Martensite
Foil
Wire Cloth
Perforated
Expanded
Clad
Embossed
High Strength
High Yield
Cor-Ten
Clad Metals
Flat and Shaped Wire
Finish
Plain Unfinished Steel
Pre-Galvanized Steel
Pre-Painted most materials
Pre-Anodized Aluminum
Pre-Plated Steel
Pre-Polished (Bright, Satin) Steel
Pre-Perforated all materials
Pre-Lacquered all materials
Pre-Laminated Vinyl all materials
Pre-Embossed
Strippable PVC on finishes
Colors
White
Black
Forrest Green
Brown
Red
Any Color
Thickness
.005 to .188 in
Width
.187 to 20 in
Length
Up to 36 ft
Coil Length
Up to 2,000 ft, and more
Spindle Diameter
1 to 2.5 in
Stroke
.5 to 4 in
Roll Outside Diameter
Up to 15 in
Weight Capacity
Up to 6,000 lbs
Roll Forming Tolerances (+/-)
.005 in some part areas, and up
.003 in (when Possible)
Inspection
First Part Customer Sample Approval Process
First Part In-house Production Sample
Final Part In-House Production Sample
Calipers
Micrometers
Optical Comparator
Surface Plate and Digital Scales
Gages made by customer or by Johnson Bros.
Testing
Material Temper
Tooling
Hardness
Finishes
Quality
Control Manager
Statistical Process Control (SPC)
ISO 9000 Compliant
Documentation
Blueprints
Inspection Reports
Corrective Action Form
Sample Approval Forms
Testing
Inspection
Safety
Employee Training
Documentation
Awards
Secondary Operations
Ring Forming
Tooling
Machining
Grinding
Hardening
Sawing
Sanding
Welding
Coating
Assembly
Packaging
Secondary Fabrication
Storage
Shipping
Receiving
Tooling
Roll Dies
Cutoff & Inline Post Fabricating Dies
Pre -Notch Dies
Secondary Fabricating Dies
Weld Fixtures
Production Volume
Under 2,000 ft, Special Agreements only.
Over 2,000 ft (Existing Tooling no Punching)
Over 5,000 ft (New Tooling, & Existing w/punching)
No Minimum on Repeat Ring Requirements
No Minimum on Lock Seam Tubing stock sizes

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