| Size (cubed) | Suggested Wall thickness |
| up to 10mm (0.4") | 0.2mm - 1.0mm (0.008" - 0.04") |
| 25mm (1.0") | 0.5mm - 1.5mm (0.02" - 0.06") |
| 75mm (3.0") | 1.0mm - 3.0mm (0.04" - 0.12") |
| 100mm (4.0") | 1.5mm - 3.0mm (0.06" - 0.12") |
| above 100mm (4.0") | 2.0mm (0.08") upwards |
Thin walls and uniform wall thickness always produce superior castings with minimum porosity, distortion and tolerance spreading.
Constant section thin walls are preferred but large changes of section can be accommodated through critical analysis of the component design and special tooling design features.
Wall thickness and flatness over large surfaces are better controlled if through-holes and ribs are incorporated in the design.
Wall section tolerances:
| mm | inch | ||
| Section | Tolerance | Section | Tolerance |
| up to 0.5 | ±0.10 | up to 0.020 | ±0.004 |
| 0.5 - 1.0 | ±0.15 | 0.020 - 0.040 | ±0.006 |
| 1.0 - 2.0 | ±0.20 | 0.040 - 0.080 | ±0.008 |
| 2.0 - 4.0 | ±0.25 | 0.080 - 0.160 | ±0.010 |
| 4.0 - 8.0 | ±0.30 | 0.160 - 0.320 | ±0.012 |
