🛠 NEMJO Flat Bar Rolling Machine

📌 Problem Statement

In metal fabrication, especially in the production of gates, railings, furniture, and structural elements, rolling flat bars into curves or rings is a frequent requirement.

• Local fabricators lack access to safe, purpose-built flat bar rolling machines.
• Imported machines are cost-prohibitive for small workshops.
• Manual bending methods produce poor quality, inconsistent results and lead to workplace injuries.

Without affordable mechanized alternatives, local craftsmen are stuck with inefficient and risky methods.

✅ NEMJO’s Practical Engineering Solution

Objective: To design a mechanised, affordable, and locally serviceable flat bar rolling machine for small-scale metal fabricators.

• 💰 Cost-effective and reproducible design
• 🔌 Operable manually or with low-powered motors
• 🛡 Safe and user-friendly operation

🔬 Research and Development Insights

• Interviews with over 40 local fabricators on common pain points
• Study of industrial-grade pinch roller mechanisms
• Analysis of cold rolling deformation and stress tolerances
• Prototype testing with multiple roller and gear configurations

🔧 Key Features & Engineering Innovations

• 🔄 Manual Crank or Low-Powered Drive: High torque with low effort, flexible power options.
• 🔺 Adjustable Top Roller: Variable bend radius, mimicking industrial systems.
• 🏗 Rugged Steel Frame: Weldable with local materials and stress-reinforced.
• 🧰 Safety-First Design: Protective roller guards and stable base.
• 📏 Multi-Size Support: Handles flat bars from 20×5mm to 50×6mm.
• 🔧 Locally Serviceable: Built with common, replaceable parts.