Wire Tolerances Guide
A quick reference guide for our standard tolerances. We inspect all phases of production and our test equipment can verify the tolerance of the wire/tape/ribbon/section/profile, surface quality, roundness, strength properties and the stress required to breaking point.
Please see our standard tolerances below.
We can offer tighter tolerances, please let us know what tolerance you require.
Wire Diameter Tolerances
(mm)
| wire diameter | up to but excluding | tolerance |
|---|---|---|
| 0.0254 | 0.203 | ± 0.0051 |
| 0.203 | 0.376 | ± 0.0076 |
| 0.376 | 0.813 | ± 0.0100 |
| 0.813 | 1.220 | ± 0.0127 |
| 1.220 | 2.030 | ± 0.0152 |
| 2.030 | 3.250 | ± 0.0203 |
| 3.250 | 4.470 | ± 0.0254 |
| 4.470 | 5.890 | ± 0.0381 |
| 5.890 | 8.000 | ± 0.0510 |
| 8.000 | 10.00 | ± 0.0635 |
| 10.00 | 21.00 | ± 0.0762 |
(inch)
| wire diameter | up to but excluding | tolerance |
|---|---|---|
| .001 | .008 | ± .0002 |
| .008 | .015 | ± .0003 |
| .015 | .032 | ± .0004 |
| .032 | .048 | ± .0005 |
| .048 | .080 | ± .0006 |
| .080 | .128 | ± .0008 |
| .128 | .176 | ± .0010 |
| .176 | .232 | ± .0015 |
| .232 | .315 | ± .0020 |
| .315 | .395 | ± .0025 |
| .395 | .827 | ± .0030 |
Wire Ovality Tolerances
(mm)
| wire diameter | up to but excluding | tolerance |
|---|---|---|
| 0.0254 | 0.0508 | ± 0.0051 |
| 0.0508 | 1.02 | ± 0.0076 |
| 1.02 | 2.03 | ± 0.0100 |
| 2.03 | 4.47 | ± 0.0127 |
| 4.47 | 8.00 | ± 0.0152 |
| 8.00 | 21.00 | ± 0.0203 |
(inch)
| wire diameter | up to but excluding | tolerance |
|---|---|---|
| .001 | .002 | ± .0002 |
| .002 | .040 | ± .0003 |
| .040 | .080 | ± .0004 |
| .080 | .176 | ± .0005 |
| .176 | .315 | ± .0006 |
| .315 | .827 | ± .0008 |
Flat Wire Tolerances
(mm)
| dimensions | tolerance |
|---|---|
| Width | ± 5% |
| Thickness | |
| 0.20 and below | ± 0.0100 |
| over 0.20 | ± 5% |
(inch)
| dimensions | tolerance |
|---|---|
| Width | ± 5% |
| Thickness | |
| .008 and below | ± .0004 |
| over .008 | ± .0005 |
Shaped Profile Tolerances
(mm)
| section size | up to but excluding | tolerance |
|---|---|---|
| up to | 2.0 | ± 0.04 |
| 2.0 | 4.0 | ± 0.07 |
| 4.0 | and below | ± 0.15 |
(inch)
| section size | up to but excluding | tolerance |
|---|---|---|
| up to | .787 | ± .0016 |
| .0787 | .157 | ± .0027 |
| .157 | and above | ± .0059 |
Straight Length Tolerances
(mm)
| diameter | length | tolerance |
|---|---|---|
| up to 2.5 | up to 1000 | ± 1.00 |
| up to 2.5 | 1000 – 2000 | ± 2.00 |
| up to 2.5 | 2000 – 3000 | ± 2.50 |
| 2.5 – 5.0 | up to 1000 | ± 2.00 |
| 2.5 – 5.0 | 1000 – 2000 | ± 2.50 |
| 2.5 – 2.50 | 2000 – 3000 | ± 3.00 |
| 5.0 – 12.0 | up to 1000 | ± 4.00 |
| 5.0 – 12.0 | 1000 – 2000 | ± 5.00 |
| 5.0 – 12.0 | 2000 – 3000 | ± 6.00 |
(inch)
| diameter | length | tolerance |
|---|---|---|
| up to .098 | up to 40 | ± .040 |
| up to .098 | 40 – 80 | ± .080 |
| up to .098 | 80 – 120 | ± .098 |
| .098 – .197 | up to 40 | ± .080 |
| .098 – .197 | 40 – 80 | ± .098 |
| .098 – .197 | 80 – 120 | ± .120 |
| .197 – .472 | up to 40 | ± .160 |
| .197 – .472 | 40 – 80 | ± .200 |
| .197 – .472 | 80 – 120 | ± .240 |
Electrical Resistance Tolerances
(mm)
| wire diameter | up to but excluding | tolerance |
|---|---|---|
| 0.0254 | 0.0508 | ± 12% |
| 0.0508 | 0.076 | ± 10% |
| 0.076 | 0.15 | ± 7% |
| 0.15 | ± 5% | |
| Flat wire | ± 5% |
(inch)
| wire diameter | up to but excluding | tolerance |
|---|---|---|
| .001 | .002 | ± 12% |
| .002 | .003 | ± 10% |
| .003 | .006 | ± 7% |
| .006 | ± 5% | |
| Flat wire | ± 5% |
