Roll forming is a faster process that uses less material, which can make it more cost-efficient for very large projects. On the other hand, the roll-forming dies and setup are more complex, more intricate, and thus more expensive.
Most industry experts agree that there are clear advantages to extruded aluminum. For one thing, the dies used in the extruded aluminum process involve a single piece of metal that is simple to fabricate and thus less costly than a roll formed die. The extruded aluminum process also allows the flexibility of adding slots and other openings during production; in roll forming, an additional post-process is required - which adds to the production time and cost.