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%
