I am working on a project for which I need to make a metal pipe by rolling 1mm thick sheet metal. I have researched online and not found easy way to make a tool. I spent some time and came up with 3d printing solution to make a sheet metal roller. I believe this is the 1st 3d printed sheet metal roller available in the internet. I have tested with 1mm thick sheet metal and it is working fine. Metal can be rolled based on the pressure applied by the two M5 bolts.

Youtube: https://youtu.be/3dJySXXvipE

sheet-metal-roller.webp
Download

Supplies

Bearings (6201ZZ) - 10pcs
12mm metal rods(18cm each) - 2pcs
12mm rod (27cm) - 1pc
8mm threaded rods (20cm each) - 4pcs
M5 Bolts (35mm each) - 2pcs
M5 Bolt (40mm) - 1pc
M5 Nuts - 3pcs
M5 Washer - 1pc
M8 Washers - 20pcs
M8 Nuts - 20pcs
3d print filament

Step 1: 3d Printed Parts

Download and print the files from printables

Left Plate - 1pc
Right Plate - 1pc
Middle Plate - 1pc
Spacer small - 4pcs
Spacer medium - 4pcs
Spacer large - 4pcs
Handle - 1pc
Shaft1 - 1pc
Shaft2 - 1pc

Step 2: Assemble Body

Insert 8mm threaded rods to left plate and screw them as shown in the images.
Insert spacers and bearing in the order: medium spacer -> bearing -> large spacer -> bearing -> small spacer.
Insert M8 Bolts -> M8 Washers -> middle plate.
Insert M8 washer -> M8 Bolts.
Insert Another set of spacers and bearing in the order: small spacer -> bearing -> large spacer -> bearing -> medium spacer.
Insert M8 bolts -> M8 washers.
Insert right plate and bolts and then screw.

Step 3: Tensioner

Insert M5 bolt in to 3d print and add M5 bolts from top. These bolts are used to increase the tension on sheet metal to roll.

Step 4: Assemble Shaft

Glue some waste metal washers as shown in image using epoxy glue. This part helps to prevent 3d part from damage while rolling the sheetmetal due to pressure.
Insert bearing in to the print and add the part to right plate.
Repeat the process one more time to make for another side.