Wall Thickness Uniformity Checker

Compare minimum and maximum CAD wall measurements with a nominal wall and a project-defined deviation screen.

Formula and method

Maximum deviation = max[(nominal − minimum) / nominal, (maximum − nominal) / nominal] × 100%.

Inputs and units

Measure the nominal wall intended by the designer and the local minimum and maximum from a CAD thickness analysis or section review. Enter the allowable percent from the material, supplier, toolmaker or project specification; the tool does not invent that tolerance.

Worked example

For a 2.5 mm nominal wall measured from 2.25 to 2.75 mm with a 10% project limit, the maximum deviation is 10%. The observed range is 0.5 mm and the allowable deviation is ±0.25 mm.

When to use it

Use before adding ribs or bosses so every secondary-feature ratio refers to a documented adjacent wall.

How to interpret the result

A result within the entered band means only that the measured extrema meet that project screen. It does not prove fill, cooling, shrinkage, strength or appearance.

Assumptions and limitations

The minimum must not exceed nominal and maximum must not be below nominal. Material-specific minimum wall, gradual transitions and flow length remain separate design decisions.

Validation guidance

Review a CAD thickness map, section the highest-risk transitions, and have the moldmaker confirm gate, cooling, steel and appearance implications.

FAQ

Does a passing screen approve the part for tooling?

No. It creates a traceable CAD review record. Formal DFM, material review, mold design, simulation where appropriate, and molded-part validation remain required.

Sources

Protolabs wall-thickness guidance · Protolabs Designing for Mouldability