Sheet Metal Machining Size Guide

Here we present a basic guide to sheet metal fabrication including important design considerations to help improve part manufacturability, enhance appearance, and reduce overall production time.

Size

Maximum Dimensions
US Metric
SIZE 39 in. x 47 in. 990.6mm x 1,193.8mm
BEND LENGTH 47 in. 1,193.8mm
Minimum Dimensions
US Metric
FLAT PART 0.250 in. x 0.250 in. 6.35mm x 6.35mm
FORMED PART 0.500 in. x 0.500 in. 12.7mm x 12.7mm

Tolerances

Single Surface
US Metric
Bends +/- 1 degree +/- 1 degree
Offsets +/- 0.012 in. +/- 0.304mm
Hole Diameters +/- 0.005 in. +/- 0.127mm
Edge to edge/hole; hole to hole +/- 0.005 in. +/- 0.127mm
Hardware to edge/hole +/- 0.010 in. +/- 0.254mm
Hardware to hardware +/- 0.015 in. +/- 0.381mm
Bend to edge +/- 0.010 in. +/- 0.254mm
Bend to hole/hardware/bend +/- 0.015 in. +/- 0.381mm
Multiple Surface
US Metric
Features separated by two or more bends +/- 0.030 in. +/- 0.762mm

Sheet Metal Material Thickness Chart

Because sheet metal parts are manufactured from a single sheet of metal, the part must maintain uniform wall thickness. Sheet metal thickness ranges from 0.024 in. (0.609mm) to 0.250 in. (6.35mm).

Steel Stainless Steel Aluminum
CRS/HRPO Galvanneal Galvanized 304-2B 304 #4 316-2B 5052-H32 6061-T6
0.024 0.024 0.024 0.024 0.024 0.024 0.025 0.025
0.029 0.029 0.029 0.03 0.03 0.03 0.032 0.032
0.036 0.036 0.036 0.036 0.036 0.036
0.042 0.04 0.04
0.047 0.047 0.047 0.048 0.048 0.048 0.05 0.05
0.059 0.059 0.059 0.059 0.059 0.059 0.063 0.063
0.074 0.074 0.074 0.074 0.074 0.074 0.080 0.080
0.089 0.089 0.089 0.089 0.089 0.089 0.093 0.093
0.104 0.104 0.104 0.105 0.105 0.105 0.10 0.10
0.119 0.119 0.119 0.119 0.119 0.119 0.125 0.125
0.134 0.134 0.134 0.134 0.134 0.134
0.160 0.160 0.160
0.179 0.1875 0.190 0.190
0.250 0.250 0.250 0.250