Use these ranges for early design checks only. Actual capability depends on material, size, geometry, finish, quantity, and inspection plan. Upload the model and identify critical dimensions, datums, and cosmetic surfaces for project-specific feedback.
| Process | Minimum wall thickness (recommended) | General tolerances (reference) | Recommended fillet/radius | Typical risk points |
|---|---|---|---|---|
| CNC Machining | Metal ≥ 0.8 mm; plastic ≥ 1.2 mm | ±0.05 mm for general reference; tighter tolerances require review | Internal radius R ≥ 0.5 mm; use a larger radius where possible | Deep cavities, thin-walls, sharp angles, deep threads, tight tolerances |
| Injection Molding | 0.8–3.0 mm, kept as uniform as possible | Subject to mold and material | Rounded transitions; draft ≥ 1° and typically ≥ 2° for texture or deep cavities | Sudden changes in wall thickness, sink marks, warping, insufficient draft, and excessive rib thickness |
| Sheet Metal Fabrication | Commonly 0.5–6 mm, depending on material | Cutting + bending requires comprehensive evaluation | Recommended inner bend radius ≥ material thickness (t) | Insufficient hole spacing, bending interference, cracking, springback, assembly deviation |
| Vacuum Casting | 1.5–4 mm (recommended) | Depends on master mold and material | Avoid sharp corners and add rounded corners and transitions | Bubbles, trapped air, thin-wall deformation, and poorly planned parting lines |
CNC machining supports precise, complex parts, but deep cavities, thin walls, sharp internal corners, tight tolerances, and difficult fixturing increase cost and lead time. Address these features early to reduce extra setups, deformation, scrap, and inspection work.
Stable molding depends on uniform wall thickness, adequate draft, controlled cosmetic features, and manageable mold complexity. For cosmetic parts, identify the primary visible surface and acceptable parting-line, ejector-mark, and gate locations before tooling review.
Bend access, hole spacing, springback, and assembly datums drive sheet metal cost and consistency. For assemblies, define a reference edge or locating hole and use slotted holes where appropriate to accommodate variation.
Vacuum casting supports low-volume prototypes with production-like appearance. Plan wall thickness, parting, venting, and cosmetic requirements early to reduce bubbles, thin-wall deformation, repair, and batch variation.
Deep features, thin walls, tight tolerances, complex tooling, and demanding finishes can raise cost and lead time. Keep strict requirements on critical functional or cosmetic areas and use standard manufacturing limits elsewhere.
Long tool reach increases vibration risk and reduces machining efficiency.
Consider: Split the design, enlarge the opening, add relief and radii, or revise the assembly.
Small diameters and high depth ratios increase tool-breakage risk and process control.
Consider: Increase diameter, reduce depth, or use an insert or through-hole fastening method.
Flexible features can deform and may require special fixtures, supports, and correction.
Consider: Add ribs or arches, thicken locally, or combine a shell with reinforcement.
Tight tolerances can require extra operations, slower machining, and more inspection.
Consider: Tighten only critical interfaces, define datums and inspection methods, and use general tolerances elsewhere.
Side actions increase mold complexity, manufacturing time, and maintenance cost.
Consider: Revise the undercut, split the assembly, or reduce the number and travel of side actions.
Grinding, painting, printing, and plating add operations and consistency risk.
Consider: Limit premium cosmetics to the primary visible surface, simplify finishes, and define acceptance areas.
Use this checklist before requesting a quote to identify common geometry, tolerance, draft, spacing, and venting risks.
Increase the internal radius, revise the geometry, or confirm a secondary process when a sharp corner is essential.
Tighten only critical interfaces; use general tolerances elsewhere and define the datum structure.
Core out thick areas, add suitable ribs, and transition wall thickness gradually to reduce sink and warpage.
Use at least 1° on common cosmetic surfaces and typically 2° or more for texture or deep cavities, subject to review.
Keep hole edges at least 1.5 × material thickness from bend lines and consider relief or slotted holes near bends.
Add radii, plan parting and venting, and split the structure or revise the pour plan where necessary.
Manufacturability also depends on measurable requirements. Define datums, critical dimension chains, cosmetic surfaces, and acceptance criteria early to reduce clarification, inspection disputes, and rework.
As an early reference, use a minimum wall thickness of ≥ 0.8 mm for metal and ≥ 1.2 mm for plastic. Thinner features require review based on material, size, geometry, and clamping method.
Rotating milling tools leave an internal radius. Specify R ≥ 0.5 mm where practical; sharper corners may require electrical discharge machining (EDM), wire cutting, or a design change.
Use at least 1° draft on common cosmetic surfaces and typically 2° or more for textured surfaces or deep cavities. Final draft depends on material, texture, depth, and tooling direction.
Keep wall thickness uniform, core out thick areas, and use ribs instead of solid blocks. Rib thickness is typically limited to about 60% of the adjoining wall, subject to material and tooling review.
Use an inner bend radius of R ≥ material thickness (t) as an early reference. Stainless steel and high-strength materials may require a larger radius to reduce cracking and springback variation.
As an early reference, keep the hole edge at least 1.5 × material thickness from the bend line; 2 × thickness is more conservative. Final spacing depends on material, tooling, and geometry.
Vacuum casting is commonly used for low-volume verification. A silicone mold may produce roughly 15–25 parts, but actual mold life depends on geometry, demolding difficulty, material, and acceptance requirements.
Sharp corners, deep cavities, abrupt thin-wall transitions, and inadequate venting can trap air. Add rounded transitions, improve parting and venting paths, or revise the pour plan or part split.
Tight tolerances may require extra operations, slower machining, and coordinate measuring machine (CMM) inspection. Apply them to critical interfaces and define the datums and acceptance method.
Provide the following where available:
