Protocase Resources

The information below is intended to be helpful for customers who wish to learn more about enclosure design. Also, please use our online support if you have questions for our expert design staff.


Fabrication Tolerances for Dimensional Variance in Aluminum Extrusion and Machined Parts

Standard Tolerances For
Structural Aluminum Extrusion

1U Extrusion

2U Extrusion

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 6063 Extrusion

Height Tolerance (Height) Tolerance (Width)
1U (Height: 1.72" | 43.688 mm) ± 0.014" | 0.36mm ± 0.010" | 0.25mm
2U (Height: 3.47" | 88.138 mm) ± 0.024" | 0.61mm ± 0.010" | 0.25mm