Aircraft Extrusion Company
180 Erma Court, Unit 180
Chico, CA 95928, USA
Phone: +1 (323) 813 4105
Email: info@aircraftextrusion.com

Forming Tolerance

Information about Rollform Dimensional Tolerance

question we get asked a lot at Aircraft Extrusion Company, "what is the bend tolerance for aluminum sheet and why is my material 2024-T42 instead of 2024-T3 or 7075-T62 instead of 7075-T6.". Basically, aircraft sheet bend tolerance that are detailed in Boeing data release specification BAC5300. The difference between 2024-T3 v's 2024-T42, and 7075-T6 v's 7075-T62 is that in the case of both 2024-T3 and 7075-T6 whether it is bare or alclad material, the temper is referred to as a "mill temper" which means that the manufacturer (mill) heat treated material when it was produced to the desired temper. In situations where the sheet material is unable to be formed in the T3 or T6 temper due to the bend radius being too tight, then material will either have to be annealed to the "0" temper or the "W" condition. After forming material in the "0" or "W" condition material is then aged to the desired temper. The mechanical properties of T3 v's T42 and T6 v's T62 are the same, the "2" on the end denotes that material has received additional heat treatment. The bend tolerance is basically the allowable radius you can form aircraft sheet before it starts to crack. In most cases if you are unable to form in the original temper you will have to anneal to the O temper, form your parts then re-heat treat.

Contact Us Today: sales@aircraftextrusion.com

Minimum Standard
Bend radius requirements for aluminum alloy sheet
Thickness in inches 2219-0, 5052-0, 6061-0 2219-T42, 2024-0, 6061-T4 2219-T31, 2219-T34 7075-0, 7178-0 2219-T62, 2219-T81, 2024-T3, 2024-T4, 6061,T6 7075-T6, 7178-T6, 2024-T36 2219-T87, 2024-T85
0.016 0.030 0.030 0.030 0.030 0.060 0.090 0.250
0.020 0.030 0.030 0.060 0.030 0.060 0.090 0.250
0.025 0.030 0.060 0.060 0.060 0.090 0.120 0.310
0.032 0.030 0.060 0.060 0.060 0.120 0.160 0.440
0.036 0.030 0.060 0.090 0.060 0.160 0.190 0.500
0.040 0.060 0.060 0.090 0.060 0.160 0.190 0.560
0.045 0.060 0.090 0.090 0.090 0.190 0.250 0.620
0.050 0.060 0.090 0.120 0.090 0.190 0.250 0.620
0.056 0.060 0.120 0.120 0.120 0.220 0.280 0.620
0.063 0.060 0.120 0.160 0.120 0.220 0.310 0.750
0.071 0.090 0.120 0.160 0.120 0.280 0.380 0.880
0.080 0.090 0.160 0.190 0.190 0.340 0.440 1.120
0.090 0.090 0.190 0.190 0.190 0.380 0.500 1.250
0.100 0.120 0.220 0.250 0.220 0.440 0.620 1.750
0.112 0.120 0.250 0.340 0.280 0.500 0.750 -
0.125 0.120 0.250 0.500 0.280 0.560 0.880 -
0.140 0.120 0.340 0.560 0.380 0.620 1.000 -
0.160 0.160 0.380 0.620 0.440 0.750 1.120 -
0.180 0.190 0.440 0.690 0.500 0.880 1.250 -
0.190 0.280 0.500 0.750 0.560 0.880 1.250 -
+/- 0.01 for 0.03 to 0.06 | +/- 0.030 for 0.090 and larger

While the aluminum industry provides standard dimensional tolerance guidelines for extruded aluminum profiles, flatness and twist, contours, straightness. The experience our team brings to each project allows us to compensate for those unique situations where standard tolerances will not be successful in the end-use part application. We understand that each extruded profile has critical features that are important to its performance. Our expertise helps us determine when tolerances must be tightened in order to achieve the fit, form and functional requirements of the end applications.

Our Capabilities


Custom Design

We work with you to develop the most cost-effective and optimal design for your product with our design engineers and with custom-made dies.


Rolled Extrusions

New advanced equipement and design development aircraft extrusion company can now offer rolled extrusions.



CNC Machining

CNC Milling up to 4ft x 12ft parts, including seat tracks and secondary oporations aluminum profiles in 7075 and 2024



Seat Tracks

Standard and none-standard types of seat tracks in stock. We also provide milling services for the round slots on the tracks.



Roll-Form Stringers

A great selections of formed angles, channels, hats and tee's in both 2024 Clad and 7075 Clad. In addition, we also have forming capabilities


Cutting

We cut to size 7075 and 2024 extruded profiles, sheet, plate and form section. In-house cutting ops help reduce time, cost and shipping weights

Some of Our Clients