Our Roll Forming Capabilities
Cardinal Manufacturing designs and builds our own roll forming machines and associated equipment, providing us with control over the entire production process. This approach not only results in secure quality assurance processes—it also puts Cardinal Manufacturing in the unique position to create a single, continuous roll forming process that contains multiple operations, customized for our customers’ various needs. This affords Cardinal the capability to produce a wide range of parts—simple or complex profiles, a variety of features or none at all, a few inches long or upwards of 40 feet. Explore our roll forming capabilities and example profiles to discover how Cardinal Manufacturing equips ourselves to serve every customer’s unique needs.
In-line Capabilities
Notching
Whether it is a simple, repeating hole pattern or a complex notching configuration consisting of a variety of shapes, sizes, and locations, Cardinal has the capability to add the required notching operations to the fast-moving roll forming operation.
Application of Protective Plastics
In order to protect the surface of pre-finished materials, Cardinal can apply protective plastics or any width prior to the roll forming process. While purchasing material with a protective plastic already applied can be a solution for simple profiles, the roll forming process can stretch, rip, or deform the plastic on more complex profiles (especially those with tight radii or multiple bends). Cardinal can apply a protective plastic that is narrower than the raw material prior to the roll form process to ensure that the visible portions of the finished part stay protected and the plastic remains tightly adhered.
Embossing/Debossing
Cardinal can emboss/deboss various shapes, such as text or logos, to your part, eliminating the need for ink or adhesives that can wear or be washed off in handling or downstream processes.
Custom Shape End Cutting
If the end of your part needs a shape other than a straight cut, Cardinal can build a custom cut-off die to cut the required shape in the end of the part.
Continuous Radius Bending
Does your application require a “curved” part with a consistent profile throughout? Provided the part maintains the same radius throughout and the profile shape allows it, Cardinal can bend your part to the desired radius during the roll forming process, after forming and before cutting.
Lock-Seam Joining
Cardinal can join the ends of the material during the roll forming process using lock seam tooling to form a closed profile without a gap.
Sub-batch Strapping/Packing
If you require small quantities of parts to be strapped/bundled before being packed in a larger skid, Cardinal may be able to do this at the roll forming machine, reducing the need for an expensive off-line secondary packing operation.
Application of Miscellaneous Materials
Cardinal can provide a custom solution for customers who require another material (such as adhesive tape, rubber inserts) to be applied in-line, eliminating the need for another operation.
Other Capabilities
Cardinal Manufacturing is committed to providing solutions to our customers’ unique and diverse needs. Our goal is to utilize any of the above listed capabilities and beyond to produce your finished part in one operation. However, sometimes the nature of the part—be it the shape, material, type of feature, or tolerances—dictates that a second operation is needed. Cardinal has an array of equipment to utilize for secondary operations, should the need arise. Please visit our Secondary Operations page for more information.
