Sheet Metal Forming

Sheet metal forming is a manufacturing process where flat metal sheets are deformed using force, typically using dies, rollers, presses or manual tools.

Bending

A box pan bending machine is commonly used in workshops and is a simple way to bend along a straight line. These machines are ideal for prototyping and small batch work.

Box pan bending is limited to a relatively fixed bend radius. It also is difficult to repeat the same bend accurately and consistently.

Image: (ADH Machine Tool, 2024)

To increase scale and consistency, the press brake is what you need. It also can do a wide range of radii and complex bends. This however does come with its limitations - higher setup time, higher tooling costs. It is also harder to account for spring-back, where the metal slightly bends back after being bent

(ADH Machine Tool, 2024)

Stamping & Pressing

Pressing sheet metal is used to create a wide range of forms. Whether that might be curved, organic forms like a car body, or even something simple like a L bracket.

(Leizi, 2024)

Image: (Leizi, 2024)

For complex shapes, sheet metal might have to be stamped or pressed multiple times, through different machines. Each machine with its own specific function (punching die, bending, trimming). (Leizi, 2024)

Deep Drawing

Deep Drawing is where a blank holds the sheet firmly to control the sliding of the workpiece and prevent wrinkles or splits. The sheet is then pushed into a opening in the die using a punch. The shape of the punch defines the final shape of the product.

(Sciencedirect.com, 2015)

Roll Forming

Each roll station slightly changes the shape of the metal until the desired outcome is complete. Roll Forming is a continuous process, and could run nonstop, however sheet metal or sheet metal coils are not continuous.

(Roller Die + Forming, 2014)

There are many factors consider when choosing a material for roll forming, like formabilty, strength, cost, corrosion resistance and aesthetics. (Dahlstrom Roll Form, 2024)

"

1. Budget: How much are you willing to invest in the material?

2. Appearance: Is aesthetics a priority

3. Durability: Will your project be exposed to harsh conditions?

4. Strength: Does your project require structural integrity or a particularly robust metal?

5. Formability: Are the desired features worth the challenges and costs of complex forming processes?

" - (Dahlstrom Roll Form, 2024)

Carbon / Alloyed Steel Roll however it can be difficult to form because of spring back. Mild Steels with a carbon content less than 0.20% are easier to form and weld

Steel is heavy, but aluminium is a lighter alternative. (Dahlstrom Roll Form, 2024)

Stainless Steel - Stainless Steels properties can widely vary based on what its alloyed with. When rolling stainless steel its important to consider spring back and hardening properties. Stainless steel is a expensive material and it is expensive to manufacture, however it is high quality, heat resistant, corrosive resistant and rust resistant. Stainless steel is resistant to absorption making it perfect for a sterile environment like a hospital, kitchen or even lab. (Dahlstrom Roll Form, 2024)

Aluminium can also widely vary its properties based on its alloying elements and heat treatment. Generally its easier to form than steel. Usually aluminium is extruded however roll forming is better if the sheet thickness is 1.5mm or below. (Dahlstrom Roll Form, 2024)

Copper Alloys, Copper is a ductile metal, making it easier to roll and form. They have similar environmental resilience to stainless steel but not as strong structurally. (Dahlstrom Roll Form, 2024)

Table: (Dahlstrom Roll Form, 2024)

Metal	Formability	Strength	Cost	Outdoor Use	Appearance	Other
Carbon Steel	Good	Good	Good	Good	Fair	Heavy
Stainless steel	Good	Good	High	Good	Excellent	Hygienic
Aluminium	Excellent	Good	Moderate	Good	Fair	Lightweight
Copper Alloys	Excellent	Excellent	High	Excellent	Excellent	Durable

Sheet Spinning

Sheet Spinning is used to create axially symmetrical round shapes. A flat circular sheet of metal is spun on a lathe and is deformed by applying force through a roller, the rollers end can spin which reduces friction, heat build-up and wear.

The roller bends the metal around a mould called a mandrel while a clamp (also known as a follower) holds it in place.

Image: (www.iqsdirectory.com, n.d.)

CNC processes have made metal spinning a lot more effective and consistent through programmable speeds and torque control. CNC is much safer than manual production methods

References

ADH Machine Tool. (2024). Press Brake vs Pan Brake: Key Differences - ADH Machine Tool. [online] Available at: https://www.adhmt.com/press-brake-vs-pan-brake/. (ADH Machine Tool, 2024)

Leizi (2024). The Ultimate Guide of Metal Stamping - Tuling. [online] Tuling. Available at: https://www.tulingmetal.com/ultimate-guide-of-metal-stamping/.(Leizi, 2024)

ENCYCLOPEDIA OF MATERIALS : metals and alloys. (2021). S.L.: Elsevier.

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‌Sciencedirect.com. (2015). Deep Drawing - an overview | ScienceDirect Topics. [online] Available at: https://www.sciencedirect.com/topics/materials-science/deep-drawing.

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‌Roller Die + Forming. (2014). Roll Forming | Custom Roll Forming Process | Roller Die. [online] Available at: https://www.rollerdie.com/roll-forming/.

Dahlstrom Roll Form (2024). A Guide to the Best Materials For Commercial Roll Formed Products. [online] Dahlstromrollform.com. Available at: https://blog.dahlstromrollform.com/best-materials-for-roll-formed-products? [Accessed 28 Dec. 2025].

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Anchor Lubricants (2024). Metal Spinning 101: Your Complete Guide to Success. [online] Anchor Lubricants. Available at: https://anchorlube.com/workshop/metal-spinning/ [Accessed 2 Jan. 2026].

www.iqsdirectory.com. (n.d.). Metal Spinning: What Is It? How Does It Work? Metal Types. [online] Available at: https://www.iqsdirectory.com/articles/metal-spinning.html.

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