Wall Thickness Checks for Enclosures

When modeling enclosures, consistent wall thickness is critical for manufacturability and strength. A common mistake is designing walls that vary too much, leading to warping or sink marks. Always start by defining a nominal wall thickness based on your material and process, typically 1.5-3mm for injection-molded plastics.

Use your CAD software's analysis tools to verify thickness. In SolidWorks, use Thickness Analysis; in Fusion 360, use Wall Thickness. Set the target thickness and tolerance. Areas in red indicate too thick, blue too thin. Adjust ribs, bosses, and corners to stay within the target range.

Pay special attention to corners and transitions. Avoid sharp internal corners; use fillets with radius at least 0.5 times wall thickness. For ribs, keep their base thickness at 60% of the main wall to prevent sink. Draft angles should be 1-2 degrees per side.

Finally, simulate the molding process if possible. Tools like Moldflow can predict fill and cooling issues related to wall thickness variations. A quick check: if your part feels lightweight and uniform in thickness, you're on the right track.

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