How thin is too thin?
Per process.
Practical limits.
Wall thickness guide per process. CNC, injection molding, casting, 3D printing each have practical limits. Specify per process.
Key principles.
0.5-0.8 mm
Aluminum CNC minimum. Below: vibration.
0.8-1.0 mm
Steel CNC minimum.
1.0-3.5 mm
Plastic injection. Uniform critical.
3-5 mm
Casting needs thicker walls for fill.
0.5-3 mm
Sheet metal range.
Process specific
SLA 0.5 mm, SLS 0.8 mm, FDM 1.2 mm.
FAQ
Why these limits?
Below: process-specific failures. Vibration, sink marks, fill issues.
Tall thin walls?
Aspect ratio matters. Height/thickness > 5: stiffness reduces.
Wall variation impact?
Variation > 25% causes warping in injection. Uniform critical.
Strength vs stiffness?
Strength via material. Stiffness via geometry (cross-section). Rib for stiffness.
Process scaling?
Production tooling enables tighter limits. Prototype slightly thicker for safety.
Material choice?
Higher-strength material allows thinner. 7075 thinner than 6061. PEEK thinner than nylon.
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