Unusual Cross -Sections & Forms come in an infinite variety of shapes as the existing tooling print examples we've given will show. It is impossible to single out any industry as the main user of these Roll Formed, Profiles, Mouldings (Moldings), and Shapes as all industries use them. The print Cross-Sectional examples shown, that we have existing tooling to produce, are by no means all we manufacture. There are many more that we cannot show as they are current customer proprietary information from our customers. Johnson Bros Metal Forming has tooling for well over 300 different parts that fall into this category that we either have existing tooling available for use on or are from proprietary tooling that our customers own and are not available for general use. Unlike Channels, it is not common to use tooling from one part to the next in this category as tooling is typically not adjustable. Slight modifications to existing tooling can be made and features such as Hemmed Edges can be performed with little or no extra die charges. Our Machines allow a typical maximum Height of parts to be 3" and widths of 15" maximum but smaller parts are very common.
A Metal Moulding (Molding) is generally made from thinner materials than Profiles and Special Shapes. Mouldings are also made from Decorative Metal in many instances. Profiles can be from thinner metals but are usually considered more structural in nature. Special Shapes is a catch-all phrase that encompasses both Metal Profiles and Mouldings. Structural Shapes are common but can also be thinner and decorative.
All metals are used in producing these parts, both Prefinished & Plain: Steel Moulding (Steel Molding), Stainless Moulding (Stainless Molding),, Aluminum Moulding (Aluminum Molding), Brass, Copper, Alloys, High Strength, Bronze, Galvanized, Wire Cloth, Clad, & Perforated. Pre-Finished metals used are: Prepainted, Preplated, Preanodized, Prepolished, Prelaminated Vinyl, Embossed, Galvanized-(G30, G60, G90, G210, Electro, Bonderized), Aluminized, Galvanneal, Galvalume, Zincro, Prelaquered, Strippable PVC Coating, Primer Coated, and more. Our Thicknesses capacities are .003" through .125" thick. Small, thinner parts can be recoiled in plain and spiral wound coils as well as cut-to-length. These parts can also be made in ring form.
Other terms for parts that fall into this category are: Rails, Trim, Slats, Tracks, Slides, Special Shaped Tubing, Flashings, Forms, Zees, Cees, Purlins, Gaskets, Panels, Reflectors, Posts, Stiffeners, Reinforcements, Brackets, Holders, Supports, Framing, Rings & Rims, Heat Transfer Plates, Fins, Busbars, Ducts, Lagging, Covers, Caps, Wireways, Scuffplates, Sections, Bars, Cable Trays, Hinging Profiles & Hinges, Strips, Trays, Plates, Diffusers, Frames, Blades, Edgings & Edges, and many more.
Profiles, Mouldings (Moldings), and Special Shapes are frequently Post-Punched in the Flying Cutoff Die and Pre-Punched in our Prepunch presses. Our cutoff operation includes End Fabricating as well as accurate Cutting-to-Length along with other fabricating that in the past were always considered as part of the Prepunch operation. Gag Punching is accomplished in the Cutoff operation as well for unequal hole and other fabricating patterns and to give closer tolerances than would be accomplished in the Prepunch. The prepunched fabrications can have the areas around it stretched and that area can distort during the roll forming operation. Preventing distortion is a big reason to post-punch. Prepunching is used very often however when post punching cannot produce the required fabrication or post punching becomes a more expensive option. Prepunching can employ many different fabrications and patterns with gag punching as well. Our capacity on length is: 4" through 40ft. Accelerators (with servo drives) and Die Boosts allow for High Speed and High Accuracy in our Flying Pre & Post Press operations. Extremely thin and Foil parts can also be cut to length in-line with these systems. Our Press Controllers provide many different fabrications and patterns in the same die and more than one Pre or Post press can be used. Our flying die presses are generally pneumatic, hydraulic & mechanical from the highest quality builders. Our roll forming machines are modernized and kept in top condition with our preventative maintenance program and many have DC and High Speed drive systems. They are made by many of the highest quality roll forming machine builders such as Yoder, Tishken, and Dahlstrom.
Parts are produced to order and stock reserve only kept for large blanket order shipping releases. Existing samples may or may not be available. Prototypes for large orders are feasible.