How it is made · Rolling Shutter Guide
How is a rolling shutter made?
A custom rolling shutter is built to order from the measured opening. At Roll-A-Shield's Tempe factory, software sizes the shutter and picks its box and motor, slats and rails are cut from stock aluminum lengths, locks and notches are CNC-machined, the curtain is assembled and hung on its axle, then the shutter is checked at four stages and packed.
Key facts
- Every manufacturing dimension is carried in eighths of an inch, and the final width and height are rounded up to the next 1/8 in before any part is cut. Roll-A-Shield data
- The cut planner allows 3/8 in for the saw blade on every slat cut. Roll-A-Shield data
- The motor is chosen by curtain weight, not square footage, with a margin of 5 lb or 5% (whichever is larger) added before sizing. Roll-A-Shield data
- Most insulated slat arrives in 5.8 m (about 19 ft) lengths, already in color. Roll-A-Shield data
- Each shutter is quality-checked at four stages, from before the box is assembled to a final parts check. Roll-A-Shield data
- Building a shutter takes about 10 business days at the factory. Roll-A-Shield data
Applies to: Roll-A-Shield aluminum rolling shutters built in Tempe, Arizona: 38 mm and 55 mm insulated and 63 mm single-wall slats, motorized, manual-override, solar, battery, crank, strap and spring operation.
Is every rolling shutter built to order?
Yes. A rolling shutter is made for one opening, so production starts from a measurement, not a shelf. At Roll-A-Shield, each order goes through a configurator that turns the clear opening into an overall size, picks the box, axle and motor, and prints a cut sheet that every station works from.
The configurator does several things before anything is cut:
- Rounds every dimension up to the next 1/8 in. Final width and height are carried in eighths of an inch.
- Picks the box size from the curtain height: the smallest box from 6.5, 7, 8, 9, 10, 12 in that fits the rolled-up curtain. See what size box a shutter needs.
- Sizes the motor by weight. Curtain weight is width × height × the slat's weight per square foot ÷ 144; the configurator adds 5 lb or 5%, whichever is larger, then takes the smallest motor that lifts it. See what size motor a shutter needs.
For a shutter that Roll-A-Shield installs, the first quality check compares the field remeasure against the cut sheet before production goes further.
What comes in, and what is made in Tempe?
Roll-A-Shield buys aluminum slat, rail, box and axle stock in long lengths, plus motors and controls from the motor makers, and does the cutting, machining, assembly and testing in its Tempe shop.
| Stock | How it arrives | What the shop does |
|---|---|---|
| Insulated (foam-filled) slat, 38 and 55 mm | Mostly 5.8 m (about 19 ft) lengths, already in color | Cut to length, notched, assembled into a curtain |
| Single-wall slat, 63 mm | Long lengths | Cut to length, notched, assembled |
| Aluminum axle | Long lengths | Cut to length and punched in-house; strap holes drilled |
| Guide rails and bottom bars | Long lengths | Cut, drilled and CNC-machined for locks |
| Motors, remotes, switches | From the motor makers | Fitted, set and tested |
Finishes are covered on powder coat vs paint.
How are the slats cut?
Slats are cut to the length on the cut sheet with a stop-set saw, and the leftover pieces are planned in advance. The saw operator checks the cut sheet for color and slat type, sets the saw stop to the slat length, and pulls a tape on the first cut to confirm it matches.
- Kerf and trim. The cut planner allows 3/8 in for the saw blade on every cut. A fresh bundle is squared off by 3/4 to 1 in before the first cut, and the end slat is faced off about 1/2 in.
- One direction. Slats are loaded so they all face the same way, and solid and vented slats are counted out to the numbers the order calls for.
- Nesting and drops. The cut optimiser packs each order's lengths into the stock, keeps reusable offcuts for later jobs, and scraps pieces too short to use.
The end slat (the bottom slat of the curtain) is labeled for its job and gets a Roll-A-Shield brand sticker on its right side.
How are the rails, axle and bottom bar prepared?
Each part is cut, then drilled or machined for how that shutter will mount and lock.
- Guide rails. The fastener-hole layout depends on the mount (surface, recessed or a combination). The top of each rail is bevelled so the slats feed in smoothly, and after drilling the exit side is deburred and lightly countersunk.
- Axle. Hanging-strap holes start 6 in in from each end of an aluminum axle and are then spaced every 12 in working inward; the straps are riveted to the tube.
- Locks and notches. The Tempe shop's own CNC mill cuts the lock openings in locking bottom bars, the lock notches along guide rails, and the notches in slats and end slats. More on how locks and rails are CNC machined.
How is the curtain assembled?
The curtain is built slat by slat on an assembly table.
- Each slat is inspected for dents on both sides, viewed at an angle so the light shows any imperfection.
- A weight bar is cut and fitted into the end slat: 4 in shorter than the end slat on slats up to 100 in, and capped at 100 in on longer ones.
- The end slat gets its end plugs; crank and strap shutters use the plugs that stop the shutter.
- The slats are slid together and the curtain length is checked with a tape against the cut sheet.
- Slat plugs are fitted to the slat ends and stapled, two staples per slat, then the other side is done the same way.
Slats hang one way only: the concave side faces out and the convex side faces the building, reversed on a reverse-mount shutter.
How does the shutter go together?
The box is built around the motor or operator, the curtain is hung on the axle, and the curtain is rolled up into the box. White T-shaped hanging straps on the axle slide onto the top slat to join the curtain to the axle.
On a manual-override motor, for example, the end caps are marked for the motor side, an access cut is made for the motor controls, the motor is bolted to its bracket, the bearing for the other end of the axle is seated in its bracket, and the crank exit is located with a mock-up wand before it is drilled. Safety plates are fitted so the slats do not catch as they move.
Before the shutter leaves, the motor's upper and lower limits are preset, and on remote-controlled shutters the remote is pre-programmed to the motor.
What happens before it ships?
Every shutter is checked at four stages: before the box is assembled, just before the curtain is rolled up, a final check, and a parts check. The full list is on what we check before a shutter ships.
A shipped shutter is packed in foam cubes inside a carton 26 to 32 in longer than the shutter, with the parts photographed before packing. See how shutters are packed and shipped.
How long does it take?
About 10 business days to build, and about 2 weeks to your door if it ships. Phoenix-area installs run 3-4 weeks from order. Details are on how long a custom shutter takes.
What next
Every shutter starts with a measurement: see how to measure for a rolling shutter, request a quote or call (480) 921-0200. For prices, see how much rolling shutters cost.
Frequently asked questions
Where are Roll-A-Shield shutters made?
In Tempe, Arizona. Roll-A-Shield has built rolling shutters to order at its own factory in Tempe, Arizona since 1979. Slats, extrusions and motors are bought in as raw stock and components; cutting, machining, assembly and testing happen in Tempe.
How precisely is a shutter built?
To the eighth of an inch. The configurator rounds the final width and height up to the next 1/8 in, and every cut length on the cut sheet is in eighths.
Why do the slats face a particular way?
The concave side of each slat faces outward and the convex side faces the building (reversed on a reverse-mount shutter). The curtain only hangs one way on the axle, so it rolls up correctly.
How long does it take to build a custom shutter?
About 10 business days to build, and about 2 weeks to your door when shipped. Phoenix-area installs run 3-4 weeks.
Parts and next step
Need a part or a hand?
Every shutter starts with a measurement. Ask for a quote, or order a shutter to install yourself. Call (480) 921-0200; the factory answers technical questions for any rolling shutter, not only ours.