News

Mar 05, 2024

Shape Corp. to offer roll

Shape Corp., a Tier-1 automotive supplier and developer of roll-forming technology based in Grand Haven, Michigan, has announced advancements in the use of complex roll-formed aluminum applications

Shape Corp., a Tier-1 automotive supplier and developer of roll-forming technology based in Grand Haven, Michigan, has announced advancements in the use of complex roll-formed aluminum applications for the automotive industry.

In collaboration with Atlanta-based aluminum manufacturer and recycler Novelis Inc., Shape says it can now offer a portfolio of roll-formed aluminum components, including rockers, battery tray crossmembers, roof bows and other structural parts.

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Shape says its engineers have spent years developing the method of roll forming ultra-high strength materials along with researching and developing complex geometries that bring value to structural automotive components. The company’s new roll-forming technology will utilize Novelis’ full automotive product line, including fully tempered high-strength 6xxx series aluminum sheet alloys.

Novelis has developed a variety of high-strength aluminum alloys including 6xxx series Advanz 6HS- s615, -s625, s650 alloys, and the high-strength 7xxx series. Novelis says these alloys have been developed to facilitate full circularity as they can achieve high recycled content without loss of performance.

Shape Corp. Product Manager Brian Oxley says, “Offering the ability to roll form complex shapes can be a game changer for automotive aluminum components. By incorporating high-strength 6xxx series aluminum provided by Novelis, we are able to optimize the roll-forming process, allowing us to create complex shapes, tight bend radii and, ultimately, more efficient, sustainable and cost-effective automotive components. This collaboration has opened new possibilities for the industry and reinforced Shape’s and Novelis’ position as leaders in materials innovation.”

According to Shape, roll forming simplifies the original equipment manufacturer (OEM) assembly process, replacing alternative methods that require multiple stampings and time-consuming assembly operations. The roll-forming process minimizes the need for secondary operations by forming in higher-strength tempers—maximizing weight savings—with passivation coatings, and with pre-pierced holes and fasteners applied in-line. Furthermore, the ability to reuse tooling for part length variation increases efficiency and reduces overall investment in production, the company adds.

Shape says its roll-formed aluminum complements its capabilities in roll-forming high-strength steels and producing high-strength, tight tolerance aluminum extrusions, especially when the aluminum extrusion application demands thin, constant wall thickness with geometries suited for roll forming.

By leveraging higher material strength levels, Shape says its engineers have developed a range of automotive applications that demonstrate the full potential of roll formed high-strength steel and aluminum. The collaboration with Novelis has allowed Shape to apply its experience in roll-forming steel to developing complex roll-formed automotive products made of high-strength aluminum sheet, it says.

“Novelis has identified new applications for our 6xxx series high-strength aluminum alloy sheet, which supports the mass production of lighter, low-carbon automotive parts,” says Jamie Zinser, Novelis’ vice president of global automotive. “We are proud to be partnering with Shape at our Customer Solution Center in Novi, Michigan, where our new roll form line will expedite the development and market introduction of these applications.”