Roll Form

AAA Air Support is not just a distributor of Aerospace Roll Form shapes, but also an Original Equipment Manufacturer. Our 15,000 square foot facility based in Wichita, Kansas provides us with expanded capability and reduced production times.

As a dominant manufacturer of roll formed products and aircraft roll form stringers for over 10 years AAA Air Support (AAA) understands aerospace manufacturing and what it takes to succeed; flexibility and responsiveness to our customers’ real needs and concerns. AAA Manufacturing is one of the largest roll forming operations dedicated to aerospace materials in the United States, employing continuous forming technology in a variety of products.

The Managing Director, Robert Smith, has 19 Years of direct Aerospace structural design and manufacturing experience. With his apprenticeship through Boeing Wichita from machinist to design engineer and management, specializing in stringer manufacture and structural design. In addition to his extensive industry experience, he has also attended courses in Six-Sigma, Kaisan and other ‘Lean’ Manufacturing concepts.

An ISO9001 and AS9100 approved manufacturer, AAA Air Support is dedicated to the supply of aerospace roll form shapes. With no minimum order we can produce as little as 12FT. Custom shapes are no problem, with in-house tooling design and manufacturing we can supply material to print at an affordable price. With a wide range of existing inventory in formed shapes available to ship next day in a variety of customer part numbers and alloys. Aerospace roll forms are critical when it comes to tolerance, and bend radius factors. AAA Air Support supplies material to BAC1480 standard tolerances unless specified. Our bend radius specification is BAC5300.

Custom Roll Forming

Tight Tolerances
Short runs welcome
In-house Tooling Design and Manufacture
Value added services available
Manufacturing Sales Terms & Conditions
Manufacturing Purchase Orders Terms & Conditions

Manufacturing ISO Certification Facility:
Our 15,000 SF building is located in Wichita, Kansas not far from the major international airport.

Our Roll Form Operation

In the video below you’ll see a roll form machine in action.
The sheet metal starts out as a flat sheet and runs through the roll form process.
It gradually comes out as a shaped c-channel at the other end.

Roll form machine without dyes on the mandrills

Tolerances on machined tooled parts are within +/- .0005 (0.0127mm). All tooling is manufactured and designed on site. Some shapes will take up to 36 separate tools to form what the shape requires. Careful planning, tool design and manufacture are vital to the roll form operation to supply a perfect part the first time and every time.

Moving metal through the rollers

Holding Tolerances @ +/- 1 Degree(s) and dimensional tolerances of +/-0.005” . Computer AUTO-CAD tool design strategically located from approved heat treater and additional processing. Production capabilities run from 1 foot to 75 foot lengths. Forming a wide range of aluminum alloys, titanium and stainless.

Machine setup with tooling on it

10 stand 8” Roll Space Yoder
10 stand 8” Roll Space Tishken Computerized Control
10 stand 8” Roll Space Yoder
12 stand 8” Roll Space Tishken
12 stand 8” Roll Space Yoder
2” Littell leveler, HD Vary Drive
2” Littell leveler, HD Vary Drive
1” Littell leveler Light, Vary Drive
1” Perfecto leveler Light, Vary Drive
1” Littell leveler Light, Vary Drive
1” Littell leveler Light, Vary Drive

All of the tooling sitting on the shelf