As manufacturers seek to minimize material costs and maximize output quality, traditional roll forming methods are no longer enough. Enter the next generation of strut channel roll forming machines—featuring post-forming servo following punching, sensor-controlled operations, and 45° fly cutting. This configuration offers an advanced solution to some of the industry's most pressing challenges: scrap reduction, punching precision, and cut quality.

Let’s examine how this intelligent system works, why it produces better results, and whether all strut channels truly need serration (tooth punching) or sensor-triggered hole cutting.

What’s Wrong with the Old Way?

Older roll forming setups usually apply:

• Punching on flat steel strips

• Manual stop-to-punch routines

• Straight hydraulic cutoff

• End trimming at start and stop of coils

While these systems are simple, they waste significant material, require constant monitoring, and produce less consistent parts.

The Zero-Waste Upgrade: Servo + Sensor + 45° Fly Cut

1. Servo Following Punching

In modern systems, the punching module is placed after forming. A servo motor drives the punch head, matching the exact speed of the moving profile. It allows:

• Precise hole placement after shaping

• Clean, distortion-free punches

• Dynamic punching distances

• Integration with sensor feedback

2. Sensor-Controlled Logic

Rather than using sensors for stop/start triggers, modern systems link sensors directly to the control logic. These sensors provide real-time data such as:

• Length positioning

• Punch count

• Profile detection

This enables accurate, automated punching and cutting without waste or delays.

3. 45° Fly Cutting

A servo tracking fly cutter executes a diagonal 45° cut while moving with the line. This creates:

• Clean edge surfaces

• No burrs or crushed ends

• Ideal joints for overlapping installations

• Continuous operation with no cutoff scrap

Why It’s Better for Product Quality

With this smart system, your strut channels will have:

• Smooth ends with precise angles

• Consistent, aligned holes

• Minimal mechanical stress

• No post-processing required

Contractors will appreciate how easily the channels align with fittings and supports. Fewer rejections mean happier clients and stronger brand reputation.

Does Every Strut Channel Need Teeth and Sensor Punching?

No. The need for serration and sensor-based punching depends entirely on the end-use.

Tooth Punching (Serrations)

Required when:

• The channel must resist vibration

• High-friction connections are needed

• Lock washers or fasteners are used

Optional when:

• The load is light

• The structure is not subject to movement

Sensor-Based Punching

Sensors allow variable distance punching, but fixed-hole products don’t need it. In high-volume production of identical parts, preset servo punching may suffice without sensor-based variation.

However, if you serve custom orders or multiple specifications in one shift, a sensor-punching combo gives you versatility without manual changeovers.

The Ideal Machine Should Include

• Servo-driven post-form punching head

• Real-time sensor integration (laser, encoder, optical)

• Multi-head tooling station (teeth, holes, slots)

• 45° servo tracking fly cutter

• PLC with touchscreen for recipes and automation

• Reinforced frame for high-speed operation

Final Thoughts

The future of strut channel manufacturing lies in intelligent, waste-free systems. By combining servo following punching, sensor-directed logic, and angled fly cutting, you can cut waste, boost productivity, and ensure every product meets strict quality standards.

Whether you’re producing solid, slotted, or serrated channels—or all of them—this flexible machine gives you the precision and adaptability to grow your business and lead in your market.