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Wall Thickness


  • Maintain a uniform wall thickness throughout your parts design
  • Thick wall design is prone to warp or other cosmetic issues
  • 10% Increase in thickness will provide 33% more stiffness with most materials

Good part design starts with optimized wall thicknesses. Wall thickness will often determine the mechanical performance, cosmetic appearance, moldability and cost-effectiveness of your plastic injection molded custom parts.

To achieve optimal wall thickness it is a balance between strength and weight which represents both durability and overall cost.

Having to add or remove material from your tooling not only adds delays to the manufacturing process but can add significant costs to your tooling.

During your design phase give careful consideration to wall thickness in order to minimize an expensive tooling change down the road.

A 10% increase in wall thickness provides approximately a 33% increase in stiffness with most materials.

Thick wall areas can sink, warp or contain voids resulting in undesired cosmetic defects.

Utilizing ribs, curves and corrugations can help you to reduce material costs and still provide rigid strength and durability in you plastic molded parts.

When designing your parts try to reach a uniform wall thickness throughout the part.

This will help you develop stronger better looking parts while also aiding in the overall look and feel by reducing blemishes that may occur from stresses during the injection molding process.

General Material Wall Thickness

  ABS 0.045 - 0.140
  Acetal 0.030 - 0.120
  Acrylic 0.025 - 0.500
  Liquid crystal polymer 0.030 - 0.120
  Long-fiber reinforced plastics 0.075 - 1.000
  Nylon 0.030 - 0.115
  Polycarbonate 0.040 - 0.150
  Polyester 0.025 - 0.125
  Polyethylene 0.030 - 0.200
  Polyphenylene sulfide 0.020 - 0.180
  Polypropylene 0.025 - 0.150
  Polystyrene 0.035 - 0.150
  Polyurethane 0.080 - 0.750