World-Class Roll Forming Workshop

Roll Into Twinsburg for World-Class 2026!

Take your roll forming knowledge to the next level at the World-Class Roll Forming Workshop, happening April 21-22 at the new Formtek, Inc. headquarters in Twinsburg, Ohio.

This immersive two-day program covers the full spectrum of roll forming, from fundamentals to advanced applications, through 12 informative sessions led by industry experts. You’ll gain beneficial insights and practical takeaways you can apply immediately on the shop floor or in design and engineering environments, see best practices in action during a guided facility tour, and connect with fellow professionals at a networking reception capped off with Roll Forming Jeopardy.

Built for shop floor workers, engineers, designers, and supervisors, this workshop blends technical depth with real-world application to help you solve challenges, optimize processes, and deliver better results.

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Event Details

World-Class Roll Forming Workshop

Date

April 21-22, 2026

Location

FORMTEK Inc

9280 Dutton Dr

Twinsburg, OH 44087-1967

Reserve a Room

Registration

Registration for this event is not currently open.

Featured Speakers

Andrew Allman

President
AMS Controls Inc
Neil Brown

President
Metform International Ltd
Kevin R Dierking

President and CEO
voestalpine Roll Forming Corp
Steve Ebel

President
Roll Form Solutions Inc
David Kinnard

Senior Sales Engineer
Tower Metalworking Fluids
Scott McMeekan

President
Ferret Inc
Brian Oxley

ShapeNext North America Leader
Shape Corp
Brian L Rodgers

Sr Applications Engineer
FORMTEK Inc
Carl Stephenson

Managing Director
Data M Sheet Metal Solutions Ltd
Chuck Summerhill

Owner
TANGENT Roll Design LLC
Paul Tiefenthal

Tooling Engineer
Meta Tool Technologies
Paul J Williams

Vice President of Business Development
Hill Engineering/FORMTEK Inc

Sessions

Session Name

Time (ET)

Registration

7:00 a.m. - 7:45 a.m.

Breakfast

7:01 a.m. - 7:45 a.m.

Welcome and Kickoff

7:45 a.m. - 8:00 a.m.

Basic to Complex Roll Form Systems

Roll forming isn’t a single process carried out on a single type of system, but a family of processes performed on a variety of systems. Learning about roll forming is a matter of learning about roll forming lines, the processes they perform, and the roles and capabilities of auxiliary equipment including seam welders.

8:00 a.m. - 9:00 a.m.

Basic Roll Design

New to roll forming? Understand basic to intermediate tooling design principles, concepts for making designs more functional, and how to determine whether a manufacturing issue is related to the tooling or the operator.

9:10 a.m. - 10:10 a.m.

Networking Break

10:10 a.m. - 10:25 a.m.

Metal Properties and Roll Forming

To successfully roll form a part, you must understand the mechanical properties of steel. The mechanical properties of steel and any variations in the material will determine how the material is roll
formed and the quality of the finished parts. Any variations and defects in the material can result in costly deformations.

10:25 a.m. - 11:25 a.m.

How to Take Roll Designs to the Next Level

This session will provide a comprehensive introduction to data M, specifically focusing on the capabilities of COPRA RF and COPRA FEA RF tools. These advanced software solutions are essential for streamlining the optimization process in design projects. To illustrate their effectiveness, the speaker will present a detailed case study that documents a project journey from initial concept to optimized design. This case highlights the challenges encountered, such as distorted holes, elongation issues, suboptimal cross-sections, and excessive force concentrations. He will delve into the FEA results that guided the optimization efforts, allowing them to identify critical areas for improvement. The transformation will be illustrated through animations that showcase the differences between the original and optimized designs. By providing a true before-and-after analysis, he aims to demonstrate the significant benefits of utilizing COPRA RF and COPRA FEA RF in achieving superior design performance and efficiency. Learn more about these insights, enabling better decision-making in your future projects.

11:35 a.m. - 12:35 p.m.

Group Lunch

12:35 p.m. - 1:35 p.m.

In-line Punching Technology

Review and understand the common in-line punching operations, including stationary flying prenotch dies, rotary punching machines, and flying post-punching dies. Plus Bring in your line upgrade questions and existing line punching problems: what line speeds are realistic for my application? How can we get better tolerances? How can we eliminate secondary operations?

1:35 p.m. - 2:35 p.m.

Roll Form Tooling Installation

The proper tooling setup is essential for the success of any roll forming operation. A good tooling setup is repeatable and can be easily adjusted as necessary. Learn how to evaluate a setup, make necessary tooling adjustments, and document your setup so it can be easily repeated in the future.

2:45 p.m. - 3:45 p.m.

Networking Break

3:45 p.m. - 4:00 p.m.

Material Handling for High Production Roll Forming

A wide variety of material handling solutions are now available for coil handling and post cut-off handling. These solutions range from very basic solutions to extremely complex. Discover the perfect system by considering the material being used, the part being formed, and post cut-off operations.

4:00 p.m. - 5:00 p.m.

Networking Reception w/Roll Forming Jeopardy Onsite

Test your knowledge and challenge your peers in a game of Jeopardy during this fun networking reception.

5:00 p.m. - 7:00 p.m.

Session Name

Time (ET)

Breakfast and Networking

8:00 a.m. - 8:45 a.m.

Tour of FORMTEK Inc

9280 Dutton Dr
Twinsburg, OH 44087

Tour the facility of FORMTEK Inc, a group of long-established metal forming equipment manufacturing companies, each with a well-known name and a history of providing innovative and reliable equipment to the metal forming and metal processing industries. Dedicated to the highest industry standard and technical accountability to their domestic and international customers, Formtek specialists are comprised of a well-built team of management, sales engineers, and support staff who pride themselves on being true experts with an in-depth knowledge of all their brands of equipment. With two dozen brands spread across eight facilities spanning three continents, as well as a network of dealers covering six continents, Formtek’s expansive network is here to support your metal forming and fabricating equipment needs. The Formtek group includes B&K, Coilmate/Dickerman, CWP, Dahlstrom, Hill Engineering, Lockformer Custom Machinery, Rowe, Tishken, Winpro, and Yoder.

9:00 a.m. - 10:15 a.m.

Lubricants Used in Production Roll Forming

There are many different types of lubricants and coolants that can be used in roll forming. The correct lubricant and coolant must be used to ensure the success of your operation. The correct lubricant and coolant can mean the different between producing a quality part or scrap. In this session learn about the different types of lubricants/coolants and develop a seven-step process to select the right lubricant/coolant for your application. In addition, explore different types of application equipment, water compatibility, and coolant monitoring.

10:15 a.m. - 11:15 a.m.

Advanced Roll Form Troubleshooting

Learn how resolve common roll forming problems that arise from the machine, tooling setups, and material conditions. In this session learn how to troubleshoot your roll form machines and tooling setups and recognize issues that arise from the material being used.

11:25 a.m. - 12:25 p.m.

Group Lunch

12:25 p.m. - 1:25 p.m.

Cutoff Technology

The sheet metal can be cut at a specific point on a roll forming line. There are different ways to make the cut depending on the location and application being used. In this session, learn the different cutoff methods and determine the best application for your cross-section. Understand slug-type cutoff dies, slugless crop cutoff dies, and combination cutoff dies and when to use them. Review the different types of presses, including air, mechanical, and hydraulic presses.

1:25 p.m. - 2:25 p.m.

Industry 4.0 and Roll Forming

Industry 4.0 is a buzzword that is still unclear to a lot of people. In this session, understand key concepts and realistic benefits of Industry 4.0, learn how these concepts can be applied to your roll forming operation, and determine which direct and opportunity costs can be eliminated.

2:35 p.m. - 3:35 p.m.

Quality Considerations for Roll Forming Processes

In this session you will identify key process variables which affect part quality, understand how incoming strip specifications impact part quality and tolerances, and learn how product design and the roll forming process are interrelated.