Custom Sheet Metal Rolling Manufacturing Service

Manufacturing Insight: Custom Sheet Metal Rolling

Precision Custom Sheet Metal Rolling: Engineered to Your Exact Specifications

At Honyo Prototype, we transform complex sheet metal rolling requirements into high-precision components through advanced CNC-controlled fabrication processes. Our custom rolling capabilities handle materials ranging from 0.5mm to 12mm thickness across aluminum, stainless steel, carbon steel, and specialty alloys, achieving tight geometric tolerances down to ±0.1° and maintaining critical material properties like tensile strength and surface integrity. Unlike standard rolling services, our engineering team collaborates with clients during the design phase to optimize part geometry, minimize springback, and ensure seamless integration with secondary operations including laser cutting, CNC bending, welding, and finishing—delivering fully assembled sub-systems from a single source.

Accelerate Your Prototyping and Low-Volume Production with Instant Quoting

Eliminate procurement delays with Honyo’s Online Instant Quote platform, designed specifically for engineering and procurement professionals. Upload your STEP, IGES, or DXF files to receive a detailed technical review and competitive pricing within hours—not days—while our manufacturing engineers validate formability, material suitability, and cost drivers before production begins. This integrated approach ensures your rolled components meet aerospace, medical, and industrial equipment standards without compromising on speed or precision.

Key Capability	Technical Scope
Material Range	Aluminum (1100-7075), Stainless (304/316), Carbon Steel (CRS/HRPO), Copper, Brass
Thickness Capacity	0.5mm – 12mm (24ga – 3/8″)
Tolerance Control	Angular: ±0.1°
Integration	Direct linkage to laser cutting, CNC press braking, MIG/TIG welding, and powder coating

Partner with Honyo Prototype to convert intricate rolling challenges into reliable, production-ready solutions—where engineering expertise meets rapid execution. Initiate your project with a validated quote today.

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Technical Capabilities

Custom sheet metal rolling involves a series of precision manufacturing processes including laser cutting, bending, and welding to transform flat sheet materials into complex, custom-shaped components. These processes are tightly controlled to ensure dimensional accuracy, structural integrity, and surface quality. Below are the technical specifications for each process as applied to selected materials: Aluminum, Steel, ABS, and Nylon.

Laser Cutting Specifications
Laser cutting provides high-precision contour cutting with minimal kerf width and excellent edge quality. It is ideal for complex geometries and tight tolerances.

Bending Specifications
Bending is performed using CNC press brakes with tooling selected based on material type, thickness, and bend radius requirements. Springback compensation and bend allowance are factored into the design.

Welding Specifications
Welding joins cut and bent components using appropriate fusion or non-fusion methods depending on material compatibility and structural requirements.

Process	Material	Thickness Range	Tolerance	Max Part Size	Tooling/Method	Notes
Laser Cutting	Aluminum	0.5 mm – 12 mm	±0.1 mm	1500 mm × 3000 mm	Fiber laser, N2 assist gas	High reflectivity; requires anti-reflective measures
	Steel (Mild)	0.8 mm – 20 mm	±0.1 mm	1500 mm × 3000 mm	Fiber laser, O2 or N2 assist	Optimal edge quality with oxygen assist for thicker sections
	ABS	1.0 mm – 6 mm	±0.2 mm	1200 mm × 2400 mm	CO2 laser, compressed air	Melts rather than vaporizes; risk of charring
	Nylon	1.0 mm – 6 mm	±0.2 mm	1200 mm × 2400 mm	CO2 laser, compressed air	High melting point; prone to warping if not clamped
Bending	Aluminum	0.5 mm – 12 mm	±0.2° angular	1500 mm × 3000 mm	CNC press brake, V-die tooling	Minimum bend radius: 0.8× thickness
	Steel (Mild)	0.8 mm – 16 mm	±0.2° angular	1500 mm × 3000 mm	CNC press brake, precision tooling	Springback compensation applied
	ABS	Not recommended	N/A	N/A	N/A	Poor structural integrity; not suited for bending
	Nylon	Not recommended	N/A	N/A	N/A	High elasticity and creep; unsuitable for precision bending
Welding	Aluminum	1.0 mm – 10 mm	±0.5 mm (joint)	Unlimited (per segment)	TIG or MIG with Ar shielding	Requires pre-cleaning to remove oxide layer
	Steel (Mild)	1.0 mm – 15 mm	±0.5 mm (joint)	Unlimited (per segment)	MIG, TIG, or spot welding	Post-weld grinding available for smooth finish
	ABS	2.0 mm – 6 mm	±0.5 mm (joint)	1200 mm × 2400 mm	Hot plate or ultrasonic welding	Solvent welding also possible for small joints
	Nylon	2.0 mm – 6 mm	±0.5 mm (joint)	1200 mm × 2400 mm	Hot gas or vibration welding	Requires precise temperature control

Notes on Material Suitability
Aluminum and steel are well-suited for full-process fabrication (laser cutting, bending, welding) due to their formability and weldability. ABS and nylon, while processable via laser cutting and limited welding, are thermoplastics that do not perform well under standard metal bending practices and are generally excluded from rolling metal fabrication workflows unless used in hybrid assemblies.

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From CAD to Part: The Process

Honyo Prototype Custom Sheet Metal Rolling Process Overview

Honyo Prototype delivers precision custom sheet metal rolling through a tightly integrated, technology-driven workflow designed for speed, accuracy, and manufacturability. Our process eliminates traditional quoting bottlenecks and proactively addresses design constraints, ensuring your rolled components meet stringent quality standards from concept to shipment. The standardized sequence is Upload CAD, AI Quote, DFM, Production, and Delivery.

Upload CAD
The process initiates when you submit your 3D CAD model (STEP, IGES, or native formats like SOLIDWORKS) via our secure online portal. Our system immediately performs initial validation checks for file integrity, unit consistency, and geometric completeness. This step captures critical parameters including material specification, sheet thickness, overall dimensions, target bend radii, and required tolerances. Accurate CAD submission is essential for downstream efficiency, as it forms the single source of truth for all subsequent stages.

AI Quote
Leveraging proprietary machine learning algorithms trained on decades of production data, our AI engine rapidly analyzes the validated CAD geometry against real-time factors. It assesses material utilization, machine setup complexity, required tooling, estimated machine hours, and labor inputs. Crucially, the AI cross-references current material market prices, shop floor capacity, and logistics costs to generate a highly accurate quote within hours—not days. This quote includes detailed cost breakdowns and a preliminary lead time estimate, all human-verified by our engineering team before client release to ensure contextual accuracy.

DFM (Design for Manufacturability)
Following quote acceptance, our engineering team conducts a rigorous DFM review focused specifically on rolling feasibility. This is not a passive check but an active collaboration to optimize your design for our rolling capabilities. We analyze minimum achievable bend radii relative to material thickness and type, verify flange lengths against machine throat depth, assess springback compensation requirements, and confirm geometric stability during the rolling process. Key parameters evaluated include:

DFM Parameter	Critical Threshold Check	Honyo Capability Range
Material Thickness	Must align with machine tonnage limits	0.5mm – 12.7mm (24ga – 1/2″)
Minimum Bend Radius	≥ 0.8x Material Thickness for most alloys	As low as 0.4x T for select materials
Max Sheet Size	Must fit within roll diameter & width capacity	Up to 3000mm x 1500mm
Tolerance Feasibility	Confirms GD&T achievable per ISO 2768-mK	Typically ±0.5mm linear, ±1° angular

Any identified risks—such as excessive thinning in tight bends or instability in large-diameter rolls—trigger immediate engineering feedback. We provide specific, actionable recommendations for design modification or process adjustment, documented in a formal DFM report requiring your approval before production release.

Production
Upon DFM sign-off, your job enters our dedicated sheet metal rolling cell. Material is cut to precise blanks using laser or shear processes, with surfaces inspected for defects. Rolling occurs on CNC-controlled pyramid or initial-pinch rolls selected based on part geometry and tolerance requirements. Real-time process monitoring tracks roller pressure, feed rate, and angular position to maintain consistency. For critical applications, in-process CMM checks validate curvature at defined intervals. All rolled components undergo final dimensional verification against your CAD model, including concentricity, ovality, and edge alignment checks. Secondary operations like welding, finishing, or assembly are sequenced inline where required.

Delivery
Completed parts undergo final QA documentation, including first-article inspection reports (FAIR) and material certification traceability. Components are packaged using anti-corrosion VCI paper and custom cradling to prevent deformation during transit. We provide full digital delivery: 3D scan data for as-rolled geometry validation, process parameter logs, and a comprehensive quality dossier. Shipments include real-time tracking, with standard lead times typically ranging from 7-15 business days post-DFM approval depending on complexity. All deliverables align with AS9100 and ISO 9001 traceability requirements, ensuring full production transparency.

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Start Your Project

Looking for precision custom sheet metal rolling? Our advanced rolling capabilities at Honyo Prototype deliver tight tolerances and consistent quality for prototypes and low-volume production.

Manufactured in Shenzhen with strict quality control, our services support a wide range of materials and thicknesses tailored to your specifications.

Contact Susan Leo today at [email protected] to discuss your project requirements and receive a fast, competitive quote.

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