Key principles.
0.5-0.8 mm
Practical CNC minimum 0.8 mm for aluminum. Below 0.5 mm vibrates and chatters.
0.8-1.0 mm
Steel minimum 0.8 mm. Tougher and stiffer than aluminum.
1.0-1.5 mm
Titanium springs back during cutting. Tighter limits than steel.
1.0-3.5 mm
Plastic injection: keep walls uniform 1-3.5 mm typical.
0.5-3 mm
Standard sheet 0.5-3 mm. Thinner becomes foil, thicker becomes plate.
Process specific
SLA 0.5 mm, SLS 0.8 mm, FDM 1.2 mm minimum.
FAQ
Below limits: vibration during machining, deflection during use, breakage in handling. Practical reliability.
Aspect ratio matters. Height/thickness > 5: stiffness reduces; vibration increases.
Min wall = strength concern. Walls thicker than min often needed for stiffness (deflection).
Mass-produced parts: well-tooled, can hold tighter. Prototypes: may need slightly thicker for safety.
Higher-strength material allows thinner. 7075 thinner than 6061. PEEK thinner than nylon.
Ribs, gussets, formed flanges add stiffness without extra wall thickness. Common DFM technique.
Get an instant quote
Send your CAD — we reply with detailed pricing, lead time, and DFM feedback within 4 working hours.
Talk to an engineer
WhatsApp our team directly. Most messages answered within 12 minutes during work hours.
Explore all services
CNC, 3D printing, injection molding, sheet metal, casting, finishing — one quality system, one partner.
Working on a live project? Send the STEP file and the two or three features you are unsure about — an engineer replies with DFM notes and a price, usually within four working hours.