Custom sections, built in Wuxi China

Customized Profile Roll Forming Machine

A customized profile roll forming machine is built from your section drawing, not from a catalogue. Developed width, thickness, hole pattern and tolerance decide the pass design, the roll set and the cutoff, so two lines that look alike on the floor can differ at every stand.

See the custom line range Send your profile drawing

Building custom lines since 2005. 500+ machines in 50+ countries. ISO 9001 certified, CE compliant.

Stacked custom roll formed profiles in different sections and materials

One drawing, one lineGuardrail, cable tray, stud, deck and greenhouse sections all come off the same engineering method, with tooling drawn for the section.

2005Building custom lines

0.3 to 6.0 mmMaterial thickness range

1,500 mmMaximum coil width

50+Export countries

ISO 9001Certified, CE compliant

How a custom line is made

Drawing in, pass plan out

A customized profile roll forming machine starts with engineering, not with steel. The flower pattern is agreed before a roll is turned, because a mistake in the pass design is cheap on paper and expensive in the workshop.

Drawing review

We start from a DWG, DXF or a dimensioned sketch. Developed width, bend radii and hole positions are checked before the line is quoted.

Pass design

The flower pattern is drawn station by station, with springback and bend allowance set from the material grade and the finish.

Tooling

Rolls are turned from Cr12MoV or ASTM 1045, hardened to 58 to 62 HRC, then ground after heat treatment to hold the profile.

Build and wire

Welded frame, gearbox drive, PLC cabinet and safety circuit are assembled in one bay, then aligned to the centre line.

Trial run

The line runs with your coil. First articles are measured against the drawing, and the pass settings are logged before packing.

Machine range

Six families a customized profile line covers

These are the sections a customized profile roll forming machine is asked for most often. Each card links to the standard line for that family, and every one of them can be widened, re-punched or re-cut for a proprietary section.

Highway guardrail roll forming line producing W beam panels

01 / Road safety

Guardrail and post lines

W beam, Thrie beam and C or sigma posts in 2.7 to 4.0 mm steel, punched to the bolt pattern of the barrier standard you build to.

2.7 to 4.0 mm18 to 24 stations12 to 20 m/min

W beam Guardrail post

Cable tray roll forming line with punching and cutting units

02 / Cable management

Cable tray, DIN rail and strut

Perforated tray, top hat rail and slotted channel, with hole patterns punched inline and side walls squared to the base.

0.8 to 2.5 mm14 to 20 stations15 to 25 m/min

Perforated tray DIN rail Strut channel

Stud and track roll forming line with servo puncher and cutter

03 / Drywall and ceiling

Stud, track and ceiling channel

C, U and omega sections from 0.4 to 1.2 mm, cut to 3 m or 6 m and stacked without a second handling step.

0.4 to 1.2 mm10 to 16 stations20 to 35 m/min

Steel stud Ceiling channel

Steel floor deck roll forming line in a workshop

04 / Deck

Floor deck and B deck

Composite deck at 550 MPa yield, with embossed ribs and end closures, plus B deck for the US market and a separate embossing line.

0.8 to 2.0 mm20 to 28 stations10 to 18 m/min

B deck Embossing line

Corrugated steel silo wall panel roll forming machine

05 / Greenhouse and storage

Greenhouse and silo profiles

Gutter connected greenhouse sections, hat fasteners and curved silo wall panels, where the radius and the hole pitch come from the structure.

0.5 to 2.0 mm12 to 20 stations10 to 20 m/min

Silo panel

Auto stacker and packing unit on a strut channel roll forming line

06 / Output

Auto stacker and line output

Stacking, counting and bundling at the end of the line, sized for the section so a two man line can run one shift without a third operator.

Bundle count1 to 6 m lengthsPLC counted

Scaffold plank

Sections outside these six families are the normal case, not the exception. A customized profile roll forming machine can be built for one proprietary part, and a line that has to change section during the week is quoted with quick change cassettes or motorized width adjustment instead.

Line configuration

What a custom line is built to

Planning ranges for a customized profile roll forming machine. The section drawing and the tolerance are quoted first, then the coil width, the punch content and the output target.

Section types	Open profiles, closed tubes, hat, C, Z, U, sigma, box and deck sections
Developed width	60 to 1,500 mm, set by the developed width of the section
Material	Galvanized, pre-painted, stainless, aluminum, copper and weathering steel
Material thickness	0.3 to 6.0 mm, with 550 MPa yield on deck and guardrail work
Forming stations	8 to 30, driven through gearbox and cardan shaft
Shaft diameter	45 to 95 mm, set by thickness and roll load
Line speed	5 to 40 m/min, set by the punch and cut cycle rather than the rolls
Tolerance	Plus or minus 0.3 mm on section width, plus or minus 0.5 mm on hole position
Punching	Hydraulic press with fixed dies, or servo punch with programmable positions
Cutoff	Post cutter, flying shear or flying saw, with a length encoder on the line
Control	Siemens or Delta PLC with HMI, inverter drive and batch counter
Electrical supply	380 V 50 Hz three phase, or 415 V, 440 V and 480 V for the destination

RollsCr12MoV or ASTM 1045, hardened to 58 to 62 HRC, ground after heat treatment, chrome plated on painted coil.
DriveGearbox per station with cardan shafts, or chain drive on light sections, sized for the heaviest section on the list.
FrameWelded steel base in 350 or 400 H beam, with a machined face for the stands and a separate bay for the press.
OptionsQuick change cassettes, motorized width adjustment, embossing rolls, auto stacker and remote monitoring.
SafetyGuarding to CE, an emergency stop at each end of the line and a lockable isolator on the cabinet.
SparesOne spare bearing set, a hardened punch insert and a roll setting chart ship with the machine.

Cost drivers

Four things that move the price

Two quotes for the same section can differ by a factor of three. These are the four choices behind the gap, and the ones to settle before a customized profile roll forming machine is ordered.

Pass design and stations

On a customized profile roll forming machine a simple hat section needs 8 to 10 stations, while a deck profile with stiffeners needs 24 or more. Every stand is a pair of rolls, a shaft, a bearing block and a motor.

Thickness and shaft size

A 6.0 mm guardrail post needs 95 mm shafts and a heavier frame than a 0.5 mm ceiling channel. Steel weight scales through the base, the drive and the decoiler.

Punch and notch content

A servo punch that moves between four positions costs more than a fixed die set, and removes the changeover when the hole pattern changes with the part number.

Automation and handling

A servo feeder, an auto stacker and a packing table add 15 to 30 percent and take one or two operators off the line, which on a customized profile roll forming machine is usually the whole payback case.

Before you order

Five things we need to quote

A customized profile roll forming machine is quoted from the section, not from a price list. Send these five and the reply is a station plan, a tooling proposal and a firm price instead of a range.

Section drawingA DWG, DXF or a dimensioned PDF with radii, angles and the developed width marked on it.
Material and gradeGalvanized, pre-painted, stainless, aluminum or copper, with the yield strength for deck and guardrail work.
Thickness rangeThe full range the line has to run, not only the nominal gauge, because shafts and roll gaps are sized for the heaviest pass.
Tolerance and finishVisible faces, hole position tolerance and any marking or embossing that has to land in a fixed place.
Output and coilPieces per shift, bundle or length, coil inner diameter and coil weight, which set the decoiler and the runout.

Flying saw cutting a roll formed strut channel to length

Sections are rolled to EN 10346 or ASTM A653 coil, and lines for the EU arrive with CE documentation under the EU CE marking rules. For the UK the same file is documented to UKCA through the GOV.UK UKCA guidance.

Build and test

Every line runs before it ships

A customized profile roll forming machine is judged on the first article, not on the brochure. Each line is assembled, wired and run in our works with the customer's coil, then measured against the drawing.

Flower pattern and springback

The pass design of a customized profile roll forming machine is simulated before the rolls are cut, with springback and bend allowance taken from the grade. Material that has been formed once cannot be re-set without marks.

First article check

Width, height, angle, hole position and cut length are measured on the first ten pieces and logged. The report ships with the machine.

Documentation and training

Roll setting charts, a spare parts list and a punch schedule arrive with the line. Remote support and on site commissioning are quoted as options.

Questions

Customized profile roll forming machine FAQ

What buyers ask before a custom line is quoted, answered in plain terms.

What is a customized profile roll forming machine?

A customized profile roll forming machine is a line built for one section that no standard machine covers. The tooling, the pass design and the cutoff are drawn from the customer's section drawing, so the machine forms that profile and its size range rather than a catalogue shape.

Can you build a line from a sample instead of a drawing?

Yes. A customized profile roll forming machine can be built from a sample: we measure it, rebuild the section as a drawing and check the developed width before quoting. A physical sample is often the fastest route when the original drawing is lost or the part is a copy of a competitor profile.

How many stations does a custom profile need?

As a rule, two passes per bend plus two finishing passes, so a hat section lands at 8 to 10 stations and a deck with stiffeners at 24 or more. The final count comes from the flower pattern, not from the rule of thumb.

What tolerance can a customized profile roll forming machine hold?

Plus or minus 0.3 mm on section width and plus or minus 0.5 mm on hole position are normal for a well set line. Tighter calls are possible on light gauge, and the cutoff tolerance is set by the shear type rather than the rolls.

Which materials and thicknesses can it run?

Galvanized, pre-painted, stainless, aluminum, copper and weathering steel from 0.3 to 6.0 mm. A customized profile roll forming machine built for 0.3 mm cladding cannot run 6.0 mm guardrail, so the thickness range is fixed at the quotation stage.

How long does a custom project take?

For a customized profile roll forming machine, drawing review takes 3 to 5 days, pass design and tooling drawings 2 to 3 weeks, and build 45 to 70 days after approval and deposit. Sea freight adds 20 to 40 days, and commissioning on site is scheduled after arrival.

How much does a customized profile roll forming machine cost?

A simple 10 to 12 station line starts near USD 40,000. A line with servo punching, a flying shear and an auto stacker lands between USD 60,000 and 120,000, and heavy guardrail or deck lines with 24 stations and 95 mm shafts go above that.

Send the profile drawing, get a pass plan

Share the section drawing, material, thickness range, tolerance and output target. Engineering replies with a station plan, a roll set proposal and a customized profile roll forming machine configuration that matches your part.

Page updated October 2026.

Request a custom line quote Contact us