Core Principle

Minimum wall thickness is a function of material rigidity, part height, and machining strategy. Thin walls vibrate (chatter) during machining, leading to poor dimensional accuracy and surface finish.

Design Guidelines

Metals (Aluminum/Steel):
• Rule of thumb: Wall thickness (T) ≥ H/32, where H is wall height
• For short walls (<20mm): Minimum 0.8mm thickness
• Use ribs to add stiffness instead of thickening entire walls

Plastics (Delrin/Nylon):
• More conservative minimum of 1.5mm recommended
• Lower rigidity requires thicker walls for stability

Cost Impact: Violating minimum thickness guidelines leads to:
• Increased machining time due to slower feeds
• Higher scrap rates from vibration-induced defects
• Need for specialized thin-wall machining strategies