Thin walls look elegant but test the process. Below a practical minimum they chatter, deflect, and scrap out.
Minimum thickness by material
- Aluminum: ~0.5–0.8 mm feasible with care.
- Steel/stainless: ~1.0 mm safer.
- Plastics: ~1.5 mm to avoid flex and creep.
Keep walls supported
Long, unsupported spans deflect under the cutting force. Add ribs, gussets, or shorter wall lengths. Machine walls last, after the part is rigidly located.
Process helps
- Light, consistent cuts (HSM-style) reduce vibration.
- Sharp tools and rigid fixtures prevent chatter.
- For very thin features, consider wire EDM or chemical etching as alternatives.
FAQ
Can I go below 0.5 mm? In aluminum, sometimes—but expect higher scrap and cost.
Better to mill or print thin walls? For true thin walls at scale, consider the right process; discuss in engineering review.
