Danville Metal leads the aerospace industry in its abilities to form exotic alloys, such as Hastelloy, Inconel, and Waspaloy. With both conventional and hydroforming capabilities, Danville Metal produces some of the most difficult shapes in the metal forming industry. We stand ready to meet your manufacturing challenges.

Danville Metals skilled technicians use a variety of conventional tools to form material. We design and manufacture most of our dies, allowing for shorter development times and lower costs without sacrificing quality and consistency.

Standard Forming Methods


Our Roll-Forming process is capable of handling material thicknesses up to .350 in aerospace alloys. Roll forming typically allows for low tooling costs, quick set up times, higher production rates and excellent part-to-part consistency.

Hydraulic Press Forming

Our hydraulic presses have a capacity of 100 to 1,000 tons and a working envelope of 33 x 33″ x .125”. Hydraulic presses are used for punching, extruding, flattening, flaring, and draw forming.


DMS has the capability of shearing materials as thin as .008” to .187” thick; widths ranging from .122” to 4 ft., and lengths spanning up to 12 ft.

Blank and Pierce

Our punch presses range from 60 to 450 tons, and are capable of handling materials up to .100” thick and sizes up to 40” square.

Brake Press

Danville Metal can perform brake press operations on materials up to .075” thick and sizes ranging up to 6 ft. in widths and indefinite lengths.

CNC Punch Press

For rapid, high-volume blanking and piercing operations, our Behrens CNC Punch Press will run materials up to .075” in thickness, and blank sizes up to 7’ wide x 40”long.

Specialized Forming Methods


Our in-house capabilities include hydro-forming. A maximum diameter blank size of 32″ can be formed.  Benefits of hydro-forming include: economical tooling, efficient production rates, and the ability to hold close tolerances on a variety of intricate shapes. Materials can be drawn slowly allowing the material to flow, which helps avoid cracking and tearing.

Expansion Forming

Expansion forming produces shapes in cylindrical parts, maintaining close tolerances in profiles, concentricity, diameters, and roundness with no tool marks.  The Grotnes expansion forming process will accept materials up to .125” in thickness and up to 36″ diameters with heights ranging to 10″.


Hydraulic Floor Press:  100 tons to 1000 tons

Maximum Material Thickness:  .125”

Maximum Material Size:  33” x 33”


Blank and Pierce

Punch Press Capabilities:  60 tons to 450 tons

Maximum Material Thickness:  .100”

Maximum Material Size:  40” x 40”

Brake Press

Maximum Material Thickness:  .075”

Maximum Material Size:  6.0’  x indefinite”

Grotnes (Stretch only – Form will depend on height and thickness)

Maximum Material Thickness:  .125”

Maximum Diameter:  36” x 10” height

Roll Form

Maximum Material Thickness:     .350”

Maximum Material Size:             4.0’  x indefinite



Maximum Material Thickness:  .300”

Maximum Material Size:  32” diameter


Behrens Punch Press (CNC)

Maximum Material Thickness:  .075”

Maximum Material Size:  7.0’ width x 40” length