How to Choose the Appropriate Sheet Metal Thickness?

In sheet metal design and manufacturing, sheet metal thickness is one of the key factors affecting structural strength, processing difficulty, appearance quality, cost, and assembly methods. Improper selection not only leads to material waste and increased production costs but may also cause problems such as deformation, vibration, and insufficient load-bearing capacity.

Common Sheet Metal Material Thickness Ranges

The commonly used thicknesses vary depending on the material. The following are common industry reference ranges:

1. Cold-rolled steel sheet (SPCC / SECC / SGCC)

• Common thickness: 0.5–3.0mm

• Applications: Chassis, cabinets, internal supports, electrical panels

2. Aluminum alloy (5052 / 6061)

• Common thickness: 1.0–5.0mm

• Applications: Industrial equipment housings, structural components, heat dissipation modules

• Features: Lightweight, good bendability

3. Stainless steel (SUS304 / SUS316L)

• Common thickness: 0.5–3.0mm

• Applications: Medical devices, food processing equipment, decorative parts

• Features: High strength, strong corrosion resistance

How to Choose Sheet Thickness? Key Factors Analysis

1. Structural Strength Requirements (Most Crucial Factor)

If components need to withstand weight, impact, or installation pressure, thicker materials should be selected:

• Load-bearing structures: ≥2.0mm

• Equipment base plate: 2.0–4.0mm (depending on weight)

• Rack frame: Typically 2.0mm or 3.0mm

If it's just for enclosure, protection, or weight reduction, thinner sheets can be used:

• House, cover: 0.8–1.2mm

• Front panel or door panel: 1.2–1.5mm

2. Equipment Appearance and Design Requirements

Appearance components generally cannot be too thin, otherwise they are prone to: deformation, noise from vibration and oil canning.

typical appearance thicknesses are as follows:

• Aluminum casing (anodizing required): 2.0–3.0 mm

• Large steel plate panels: 1.2–1.5 mm

3. Processing Limitations

Different processes have different requirements for plate thickness.

Bending

• The thicker the plate, the larger the minimum bending radius.

• For hard materials (such as stainless steel), bending a 1.0mm thick plate is already quite difficult.

Laser Cutting

• Thin plates are cut quickly and without burrs.

• Thick plates require higher power and are more expensive.

Welding

• Thin plates are prone to burn-through (<1.0mm).

• Thick plates are more difficult to control deformation.

Therefore, for parts with complex structures and many bends, 0.8–1.5mm thickness is generally safer. For thin plates that need to be welded, ≥1.0mm thickness is preferable.

For lightweight products (such as medical devices and aerospace components), thinner materials or aluminum alloys are preferred. If portability or weight reduction is required, 0.8mm steel plates can be used instead of 1.0mm, or 1.5mm aluminum plates can be used instead of 1.0mm steel plates.

Cost Factors (Material Costs + Processing Costs)

Thicker Material:

• Higher Unit Price

• Increased Laser Cutting and Bending Costs

• Increased Risk of Welding Deformation

• Increased Post-Processing Costs

Therefore, while meeting strength and appearance requirements, the thinnest available material should be selected to reduce costs.

Typical Plate Thickness References (Essential for Engineers)

1. Chassis and Rack Types

• Outer Shell: 1.0–1.2 mm

• Door Panels, Exterior Components: 1.2–1.5 mm

• Internal Structural Components: 1.2–1.5 mm

• Base Plate or Load-Bearing Components: 2.0–3.0 mm

2. Medical Equipment Outer Shells

• Aluminum Outer Shell (Anodized): 2.0–3.0 mm

• Internal Brackets: 1.2–2.0 mm

• Front Panel: 1.5–2.0 mm

3. Automated Equipment Structural Components

• Packets, Brackets: 2.0–4.0 mm

• Reinforcing Beams: 3.0 mm

4. Consumer Electronics and Small Cabinets

• Outer Shell: 0.6–1.0 mm

• Internal Partitions: 0.8–1.2 mm

Choosing the right sheet metal thickness is one of the most critical decisions during the design phase.The correct thickness not only ensures structural reliability and aesthetic appeal but also significantly reduces costs and improves production efficiency.

In actual projects, a comprehensive assessment should be made considering structural strength, appearance requirements, processing technology, weight, cost, and industry standards. The optimal version should be further determined through sample verification and process optimization.