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SPECIFYING CORNER RADII

For radii, tolerances range from ±0.008"/0.2 mm (nominal dimensions 0.020"/0.5 mm to 0.118"/3 mm) to ±0.079"/2 mm for dimensions from 1.181"/30 mm to 4.724"/120 mm. Alternatively, you can specify R=0 (sharp edge) punched for an additional charge.

Aesthetics play a significant role in the selection of corner radii, especially for consumer-facing products. Rounded corners typically have a more sleek, modern and polished appearance, while sharp corners can make an enclosure appear harsh or less finished. Smooth, rounded edges are often chosen for aesthetic reasons in consumer electronics, medical devices and high-end appliances.

The size of the enclosure also impacts the desired radius. For smaller enclosures, slightly larger radii might be necessary for a smooth, ergonomic look. Larger enclosures may benefit from more moderate radii that still maintain a smart appearance.

Softer plastics are easier to machine with smaller radii, while harder or tougher plastics may require larger tools and radii to avoid excessive tool wear or material deformation. Achieving a precise radius – especially for small corners – may be more challenging with certain plastics due to material properties such as brittleness or tendency to chip. Larger radii tend to be easier to machine consistently, especially in higher-volume production runs.

Smaller corner radii can be difficult to finish cleanly in some materials, especially if they are prone to smearing, chipping or melting during machining. Larger radii tend to have better surface finishes, as there is less heat generated and less material deformation during the cutting process.

Designers may choose a specific corner radius to align with the brand’s aesthetic identity. For example, a brand that prioritises sleek, contemporary designs may choose larger radii for a softer look.

Softer plastics such as ABS are generally more forgiving and can handle smaller radii without cracking or breaking. These materials can often tolerate sharper corners, though larger radii are often preferred to enhance aesthetics and reduce stress concentrations.

More rigid plastics such as ASA+PC and PMMA can be more prone to cracking, especially under stress or impact. For these materials, larger corner radii are recommended to reduce the risk of stress concentrations and to improve impact resistance.