Door Roll Forming Machines: 7 Frame Panel Profiles for 2026

Darren Mao
نوفمبر 5, 2026

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Door Manufacturing Roll Forming: Residential to Industrial Applications

الإجابة المختصرة: Door roll forming covers two product families that rarely share a machine. Frames run 1.2 to 2.0 mm gauge at 12 to 25 m/min and need heavy stands. Leaf skins and slats run 0.4 to 0.8 mm at 25 to 40 m/min and need speed. Buying one line for both is the most common mistake in this sector.

A door factory that quotes a steel frame, a garage door and a rolling shutter from one machine is describing three different tolerance regimes. The frame has to hold a 90 degree corner and a hinge pattern. The skin has to stay flat enough to paint. The slat has to interlock without rattle.

This guide separates the seven profiles door roll forming produces, and marks where the machine specification changes rather than just the tooling.

What Door Roll Forming Covers

Door roll forming covers seven profiles across three markets. Residential work takes frames, skins and garage slats. Commercial work adds fire rated frames and heavy shutters. Industrial work adds grille and insulated curtain.

المقطع	Gauge	سرعة الخط	حوامل التشكيل
إطار باب فولاذي	1.2 إلى 2.0 mm	12 to 25 m/min	16 to 24
Door leaf skin	من 0.4 إلى 0.8 مم	30 to 45 m/min	من 12 إلى 16
Garage door slat	0.4 إلى 0.7 مم	20 إلى 35 م/دقيقة	14 إلى 20
Shutter curtain slat	من 0.4 إلى 0.8 مم	20 إلى 35 م/دقيقة	من 14 إلى 18
Fire rated frame	1.5 إلى 2.0 مم	10 إلى 18 م/دقيقة	20 to 24
Frame stiffener	0.8 إلى 1.5 mm	25 إلى 40 م/دقيقة	10 to 14
Threshold and sill	0.8 إلى 1.5 mm	20 إلى 35 م/دقيقة	من 12 إلى 16

The gauge column explains most of the cost difference between quotations. Two door roll forming lines with the same footprint can differ by a factor of two in price, because one is built for 0.5 mm skin and the other for 2.0 mm frame.

Frame Lines and Skin Lines Are Different Machines

A steel door frame line is a heavy gauge mill with a notching station and a corner cut. A skin line is a light, fast mill with a leveler and a paint-safe roll surface. They share a control system and nothing else.

البند	Frame line	Skin line
قطر العمود	90 to 120 mm	55 to 70 mm
Roll diameter	240 to 300 mm	150 to 190 mm
Drive per stand	7.5 to 11 kW	2.2 to 4.0 kW
مفك اللفة	5 إلى 10 طن	3 to 5 t
Extra station	Notching, miter cut	Edge trim, leveler

Frame gauge drives shaft size for the same reason it does in racking: bending force scales with thickness squared, and deflection falls with the fourth power of shaft diameter. A 1.5 mm frame at a 6 mm inside radius needs roughly nine times the force of a 0.5 mm skin.

That is why door roll forming is usually bought as two lines, even in a small plant. The alternative is one line derated to the heavier gauge, which then runs skin at half the speed it could reach.

Springback at 90 Degrees on 1.5 mm Frame

A door frame is a closed box with two 90 degree corners, and both have to close without a gap. On any door roll forming line at 1.5 mm and 350 MPa yield, springback at a 6 mm radius runs 2.5 to 3.5 degrees.

The line handles that with overbend in the last forming passes and a sizing station that recuts the angle. What it cannot handle is variation. A coil with a 60 MPa spread in yield will produce frames that close on Monday and gap 0.8 mm on Thursday.

Gauge	Inside radius	الارتداد المرن	Correction
1.2 مم	4 mm	2.0 to 2.5 deg	Overbend plus one sizing pass
1.5 مم	6 مم	2.5 to 3.5 deg	Overbend plus two sizing passes
2.0 مم	8 mm	3.5 to 4.5 deg	Overbend, sizing, and post-form calibration

So on any door roll forming line the mill certificate matters as much as the roll design. Specify a maximum yield spread of 40 MPa and the process becomes repeatable. Leave the grade open and the operator spends the shift chasing the gap.

Punching Hinges Before Forming

Hinge positions, lock case cutouts and fixing holes all go in on flat strip. Punching after forming is possible but the die then has to reach inside a 90 mm deep box, and the burr lands on the visible face.

Hinge spacing is the number that decides whether the door hangs. Two hinges 1,200 mm apart with a 1.0 mm position error will bind a 40 kg leaf. Door roll forming lines therefore run a servo feed with hole pattern tolerance at plus or minus 0.3 mm, and a punch that combines hinge, lock and fixing holes in one stroke to avoid accumulating error across stations.

Lock case cutouts are the exception. They are large, often 200 mm by 25 mm, and they are usually routed after forming because a punch that size distorts the frame face at 1.5 mm. Cutting them inline works only with a support mandrel inside the section.

ال دليل تركيب قالب الكبس covers the alignment sequence that keeps hinge pitch stable across a die change.

Fire Rated Frames: Gauge, Groove, and Paper

A fire rated frame looks like a standard frame with one extra groove. That groove holds the intumescent seal, and its position and depth are part of the certification.

Fire door assemblies are tested as a system under NFPA 80 in North America and EN 1634 in Europe, the latter published by the British Standards Institution. The frame gauge, the corner joint and the seal groove all appear in the listing, so a frame produced on a line that was not part of the test is a different product.

المتطلب	القيمة النموذجية	Where it lands on the line
Frame gauge	1.5 mm minimum	Roll set and shaft size
Seal groove	10 by 4 mm	Extra forming pass
Corner joint	Welded or mechanically locked	Notch geometry
Anchor spacing	600 mm maximum	نمط التثقيب

Most fire rated door roll forming runs at 10 to 18 m/min, slower than a standard frame line, because the extra groove adds a pass and the gauge tolerance is tighter. Plants that run both usually keep one line and accept the slower rate rather than buy a second mill for a niche product.

Slat Lines for Garage Doors and Shutters

Garage door slats and shutter slats are the volume product in door roll forming. A sectional garage panel runs 0.4 to 0.7 mm prepainted steel, 40 to 80 mm high, with a hinge groove on each edge and a foam-filled core on insulated versions.

The interlock is the whole product. A slat that hooks correctly will not rattle when the door moves. A slat 0.15 mm out on the hook radius will, and the noise is what customers complain about first. The Door and Access Systems Manufacturers Association publishes the cycle and slat tests behind that standard.

Speed here is limited by the foaming line, not the mill. An insulated panel line runs 15 to 25 m/min through the foamer even when the roll former can do 35. The PU foamed roller shutter door line covers the inline foaming arrangement, and the rolling shutter bottom bar machine shows the finishing profile that closes the curtain.

Coating choice follows the same rule as roofing. Prepainted coil hides forming marks but scratches at the roll gap, so door roll forming on PPGI needs polished rolls and a strip guide that does not touch the face.

ما يجب ذكره في الاستفسار

Five numbers decide a door roll forming quotation:

Gauge range, and whether frame and skin are on one line or two
Profile drawings with the corner radius and interlock radius marked
Hole pattern, including hinge pitch and lock cutout size
Annual output per profile, which sets decoiler and line count
Fire rating or wind class the finished door must pass

A frame line with notching and miter cut sits at the top of the range. A skin line without punching sits at the bottom. Most plants buying their first door roll forming line start with the frame, because frames carry the margin and the machine is harder to source locally.

For the finished product side, see the آلة تشكيل هياكل الأبواب الفولاذية بالدرفلة و garage door machine pages. The steel door production line overview covers how frame, leaf and finishing stations fit together, and coil selection covers the grade and coating calls above.

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We size door roll forming lines against your gauge range and hole pattern.

الأسئلة المتكررة

Q: Can one door roll forming line make frames and door skins?

Not well. Frame work runs 1.2 to 2.0 mm and needs 90 to 120 mm shafts. Skins run 0.4 to 0.8 mm and form best on a light, fast mill. A single line derated to frame gauge runs skins at about half speed.

Q: How thick is a steel door frame on a door roll forming line?

1.2 to 1.4 mm for residential interior frames and 1.5 to 2.0 mm for exterior and fire rated work. Below 1.2 mm the frame distorts when anchors are tightened.

Q: Why do door frames gap at the corner?

Springback at the 90 degree corner, plus yield variation between coils. At 1.5 mm the springback is 2.5 to 3.5 degrees, so door roll forming needs overbend and a sizing pass, and a yield spread held under 40 MPa.

Q: Are hinge holes punched before or after forming on a door roll forming line?

Before. Punching on flat strip keeps the hole edge clean and lets one stroke carry hinge, lock and fixing holes. Routing after forming is used only for large lock case cutouts.

Q: What makes a fire rated frame different?

An intumescent seal groove, a 1.5 mm minimum gauge, and a tested corner joint. All three appear in the NFPA 80 or EN 1634 listing, so the frame has to come off a line built to that specification.

Q: How fast does door roll forming run?

12 to 25 m/min on frames and 30 to 45 m/min on skins. Fire rated frames drop to 10 to 18 m/min because the seal groove adds a forming pass.

آخر تحديث: 2026-11-05

سجل تغييرات المقال

2026-11-05: Initial publication, backfilled into the 2026-10-30 calendar slot.

محفزات المراجعة التالية

NFPA 80 or EN 1634 revises frame gauge requirements; a buyer requests a 2.5 mm frame; prepainted coil prices shift the standard from post-painted to PPGI.