Aluminum Plate Thickness Chart: Complete Guide to Sizes, Applications, and Selection

When working with aluminum plate in industries such as construction, aerospace, transportation, or fabrication, one of the most crucial factors is thickness. Selecting the correct aluminum plate thickness ensures structural integrity, cost efficiency, and performance for your project. Whether you’re designing custom components, building structures, or machining parts, understanding thickness standards is key.

In this SEO-focused article, we will break down the aluminum plate thickness chart, explain how to read it, compare metric and imperial units, and guide you through the most common applications for each thickness range.

This guide is brought to you by sasaaluminum, your trusted source for premium aluminum plates, sheets, and coils—engineered to meet the needs of professionals around the world.

1. What Is Aluminum Plate?

Aluminum plate refers to flat-rolled aluminum with a thickness typically greater than 6.0 mm (0.25 inch). It is manufactured in various grades such as 6061, 5052, 5083, and 7075, each offering different mechanical properties, corrosion resistance, and workability.

Understanding thickness categories is essential:

• Aluminum sheet: 0.2 mm to 6.0 mm

• Aluminum plate: Over 6.0 mm

Different industries may define “plate” slightly differently, but most suppliers follow these general standards.

2. Why Thickness Matters

The thickness of an aluminum plate directly impacts:

• Strength and structural support

• Weight and portability

• Weldability and machinability

• Cost and material waste

Choosing the right thickness saves time and money, reduces over-engineering, and ensures safety.

3. Aluminum Plate Thickness Chart (inches and mm)

Here’s a general reference guide comparing aluminum plate thicknesses in inches, millimeters, and gauge numbers (though gauge is less common in plate applications):

Note: Always check with sasaaluminum for custom thickness availability.

4. Metric vs Imperial Thickness

Many international projects use millimeter-based sizing, especially in Europe and Asia. However, U.S. industries often refer to inches or fractional thicknesses.

Example:

• 1/4″ = 6.35 mm

• 3/8″ = 9.52 mm

• 1/2″ = 12.7 mm

• 1″ = 25.4 mm

Both units are widely accepted, and at sasaaluminum, we offer full support for metric and imperial dimensions.

5. Choosing the Right Thickness for Your Project

When selecting thickness, consider:

5.1 Load Requirements

Thicker plates are ideal for high-load or structural applications, while thinner plates may suffice for lightweight paneling or enclosure covers.

5.2 Welding and Bending

Thinner aluminum is easier to bend and weld, while thicker plates require preheating or special techniques.

5.3 Precision Machining

Thicker aluminum plates provide more material for CNC milling, drilling, and tapping—ideal for custom parts.

5.4 Corrosion Exposure

If the material will be exposed to harsh conditions, pairing the correct grade and thickness will extend longevity.

6. Common Applications by Thickness

• 0.25″ (6.35 mm): Door panels, small platforms, cabinetry

• 0.375″ (9.5 mm): Transportation chassis, covers, framing

• 0.5″ (12.7 mm): Engine parts, marine flooring, machine beds

• 0.75″ (19 mm): Industrial tanks, base plates

• 1″+ (25.4 mm and up): Aerospace, military armor, precision molds

sasaaluminum offers custom cutting and fabrication services to match each application perfectly.

7. Grades and Thickness Compatibility

Each aluminum alloy behaves differently depending on thickness:

• 6061-T6: Great strength-to-weight ratio, weldable, ideal for 0.25″–2″ plates

• 5052-H32: Marine grade, excellent corrosion resistance, often used at 1/4″–1/2″

• 5083-H116: Exceptional marine and structural use, typically used in thick plates

• 7075-T651: Aerospace-grade, strong but less corrosion-resistant, used from 0.5″ to 2″+

Check with sasaaluminum for material certifications and best combinations of grade and thickness.

8. How to Measure Aluminum Plate Thickness Accurately

To ensure accuracy in purchasing and fabrication:

• Use a calibrated caliper or micrometer

• Measure at multiple points to account for manufacturing tolerances

• Round to the nearest industry-standard size (e.g., 1/2″, 3/4″, etc.)

Always confirm thickness before machining, welding, or bending to avoid costly errors.

9. Custom Cutting and Ordering Tips

When ordering aluminum plate:

• Specify grade, temper, thickness, width, and length

• Request saw-cut, waterjet, or CNC cut-to-size

• Ask about minimum order quantities (MOQs) for rare thicknesses

• Inquire about protective film if surface appearance matters

sasaaluminum makes it easy to customize your order to exact project specs—delivered globally with fast lead times.

10. Why Choose sasaaluminum for Aluminum Plate Products

sasaaluminum is a leading supplier of aluminum sheet and plate solutions for global industries. When you choose us, you get:

• Accurate thickness and flatness control

• A wide range of grades and dimensions

• Expert support for selection and applications

• Fast delivery and export-ready packaging

• Compliance with ASTM, EN, GB/T, and JIS standards

Whether you need standard 6061 aluminum plate or custom marine-grade 5083 material, sasaaluminum is your trusted partner for quality and performance.

11. Conclusion

Understanding the aluminum plate thickness chart helps you select the right material for strength, weight, and function. From basic fabrication to advanced aerospace parts, thickness determines success.

Refer to this guide any time you’re sourcing or specifying aluminum plate, and contact sasaaluminum for premium products, technical support, and customized service.