Specialized CNC 3-roll 60

CHALLENGE

Design and manufacture a specialized 60″ roll forming system capable of producing high-quality tubes ranging from 3″ to 24″ in diameter, with lengths up to 60 inches.

The system needed to:
• Form multiple alloys and thicknesses, including stainless steel galvanized steel, aluminized steel, aluminum, and carbon steel
• Produce a seam gap under 0.250″ (6.0mm) for the laser, plasma, Tig or MIG welding process
• Automatically feed sheet from a pallet, auto-roll, auto-eject the tube, and deliver it to a seam welder operator
• Operate with high precision and store hundreds of recipes for rapid changeovers between tube sizes and materials

SOLUTION

Weldlogic Engineering rose to the challenge by designing a CNC-controlled, servo-driven 3-roll forming systemengineered from the ground up for versatility, precision, and repeatability.

Rolling 3″ diameter stainless steel tubes at 60″ lengths requires a small top roll, which normally risks deflection under load. To counter this, our team developed a custom top roll deflection support beam spanning the full 60″ lengthen-suring consistent geometry and eliminating deflection, even at small diameters.

Key features include:
• 3″-24″ diameter capacity • Up to 60″ length
• AC servo-driven precision • Up to 500 roll forming recipes stored
• Top roll deflection beam for consistent forming
• Available in manual infeed + auto roll/eject, or fully automated configuration
This specialized CNC 3-roll system sets a new standard for multi-diameter tube rolling in demanding production environments.