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Fabrication Tolerances for Dimensional Variance in Aluminum Bar Stock and Machined Parts

Standard Tolerances For Aluminum Bar Stock

Usually, choosing material thickness is one of the first steps a designer takes when starting a project. We work with nominal thicknesses, so it's important to know the thickness tolerance on the material you chose, in order to know if the final product will be suitable for your application. It's also important when working with bar stock that you factor in finish tolerances. For example, if you add a finish such as powdercoat, you add more thickness - this should be factored into your design at the beginning.

Stocked Aluminum FLAT Bar Stock

Specified Thickness Alloy Tolerance
1/2" x 3/4" | 12.70mm x 19.05mm 6061-T6 ± 0.024" | 0.61mm
1/2" x 1" | 12.70mm x 25.4mm 6061-T6 ± 0.012" | 0.30mm
1/2" x 2" | 12.70mm x 50.80mm 6061-T6 ± 0.024" | 0.61mm
1/2" x 4" | 12.70mm x 101.60mm 6061-T6 ± 0.034" | 0.86mm
3/4" x 3/4" | 19.05mm x 19.05mm 6061-T6 ± 0.010" | 0.25mm
3/4" x 2" | 19.05mm x 50.80mm 6061-T6 ± 0.024" | 0.61mm
3/4" x 4" | 19.05mm x 101.60mm 6061-T6 ± 0.034" | 0.86mm
1-1/2" x 2" | 38.10mm x 50.80mm 6061-T6 ± 0.024" | 0.61mm
1-1/2" x 3" | 38.10mm x 76.20mm 6061-T6 ± 0.024" | 0.61mm
1" x 2" | 25.40mm x 50.80mm 6061-T6511 ± 0.024" | 0.61mm
1" x 4" | 25.40mm x 101.60mm 6061-T6511 ± 0.034" | 0.86mm
1" x 6" | 25.40mm x 152.40mm 6061-T6 ± 0.044" | 1.18mm
2" x 2" | 50.80mm x 50.80mm 6061-T6511 ± 0.024" | 0.61mm
2" x 3" | 50.80mm x 76.20mm 6061-T6511 ± 0.024" | 0.61mm
3" x 3" | 76.20mm x 76.20mm 6061-T6 ± 0.034" | 0.86mm

Stocked Aluminum ROUND Bar Stock

Specified Thickness Alloy Tolerance
1" | 25.4mm 6061-T6 ± 0.012" | 0.30mm
1.5" | 38.1mm 6061-T6 ± 0.014" | 0.36mm
2" | 50.8mm 6061-T6 ± 0.024" | 0.61mm
2.5" | 63.5mm 6061-T6 ± 0.024" | 0.61mm
3" | 76.2mm 6061-T6 ± 0.024" | 0.61mm
4" | 101.6mm 6061-T6 ± 0.034" | 0.86mm
6" | 152.4mm 6061-T6 ± 0.044" | 1.18mm