Design guidelines
Laser cutting
14 grades
116 stock records

Minimum hole size chart.

The smallest hole we laser cut in every stocked grade, thickness and finish — the same limits as our material pages. Above the recommended size it cuts clean. Between the two limits it may taper. Below the minimum, we laser mark the center so you can drill it to size.

Hole detail / sheet and plate

Check a hole Material Thickness · finish Hole diameterin

Compare materials

Minimum laser-cut hole sizes by material, thickness and finish
Material	Finish	Thickness	Min recommended	Min hole size	Recommended ÷ t	Marked below
1095 spring steel, hardened	Hardened	0.005″	≥ 0.020″	≥ 0.010″	4.00 t	< 0.010″
1100-H14	Mill	0.090″	≥ 0.045″	≥ 0.022″	0.50 t	< 0.022″
1100-H14	Mill	0.125″	≥ 0.063″	≥ 0.031″	0.50 t	< 0.031″
1100-H14	Mill	0.188″	≥ 0.094″	≥ 0.047″	0.50 t	< 0.047″
304	#4 Brushed	0.024″	≥ 0.020″	≥ 0.010″	0.83 t	< 0.010″
304	#4 Brushed / 2B	0.036″	≥ 0.020″	≥ 0.010″	0.56 t	< 0.010″
304	#4 Brushed / 2B	0.048″	≥ 0.024″	≥ 0.012″	0.50 t	< 0.012″
304	#4 Brushed / 2B	0.060″	≥ 0.030″	≥ 0.015″	0.50 t	< 0.015″
304	#4 Brushed / 2B	0.075″	≥ 0.037″	≥ 0.019″	0.49 t	< 0.019″
304	#4 Brushed / 2B	0.100″	≥ 0.050″	≥ 0.025″	0.50 t	< 0.025″
304	#4 Brushed / 2B	0.120″	≥ 0.060″	≥ 0.030″	0.50 t	< 0.030″
304	#4 Brushed / 2B	0.135″	≥ 0.068″	≥ 0.034″	0.50 t	< 0.034″
304	#1 HR Plate	0.188″	≥ 0.094″	≥ 0.047″	0.50 t	< 0.047″
304	#1 HR Plate	0.250″	≥ 0.125″	≥ 0.063″	0.50 t	< 0.063″
304	#1 HR Plate	0.375″	≥ 0.188″	≥ 0.094″	0.50 t	< 0.094″
304	#1 HR Plate	0.500″	≥ 0.250″	≥ 0.125″	0.50 t	< 0.125″
304	#1 HR Plate	0.625″	≥ 0.313″	≥ 0.156″	0.50 t	< 0.156″
316	2B	0.036″	≥ 0.020″	≥ 0.010″	0.56 t	< 0.010″
316	2B	0.048″	≥ 0.024″	≥ 0.012″	0.50 t	< 0.012″
316	2B	0.060″	≥ 0.030″	≥ 0.015″	0.50 t	< 0.015″
316	2B	0.075″	≥ 0.037″	≥ 0.019″	0.49 t	< 0.019″
316	2B	0.100″	≥ 0.050″	≥ 0.025″	0.50 t	< 0.025″
316	2B	0.120″	≥ 0.060″	≥ 0.030″	0.50 t	< 0.030″
316	2B	0.135″	≥ 0.068″	≥ 0.034″	0.50 t	< 0.034″
316	#1 HR Plate	0.188″	≥ 0.094″	≥ 0.047″	0.50 t	< 0.047″
316	#1 HR Plate	0.250″	≥ 0.125″	≥ 0.063″	0.50 t	< 0.063″
316	#1 HR Plate	0.375″	≥ 0.188″	≥ 0.094″	0.50 t	< 0.094″
5052-H32	Mill	0.020″	≥ 0.020″	≥ 0.010″	1.00 t	< 0.010″
5052-H32	Mill	0.032″	≥ 0.020″	≥ 0.010″	0.63 t	< 0.010″
5052-H32	Mill	0.040″	≥ 0.020″	≥ 0.010″	0.50 t	< 0.010″
5052-H32	Mill	0.050″	≥ 0.025″	≥ 0.013″	0.50 t	< 0.013″
5052-H32	Mill	0.063″	≥ 0.032″	≥ 0.016″	0.51 t	< 0.016″
5052-H32	Mill	0.080″	≥ 0.040″	≥ 0.020″	0.50 t	< 0.020″
5052-H32	Mill	0.090″	≥ 0.045″	≥ 0.022″	0.50 t	< 0.022″
5052-H32	Mill	0.100″	≥ 0.050″	≥ 0.025″	0.50 t	< 0.025″
5052-H32	Mill	0.125″	≥ 0.063″	≥ 0.031″	0.50 t	< 0.031″
5052-H32	Mill	0.160″	≥ 0.080″	≥ 0.040″	0.50 t	< 0.040″
5052-H32	Mill	0.188″	≥ 0.094″	≥ 0.047″	0.50 t	< 0.047″
5052-H32	Mill	0.250″	≥ 0.125″	≥ 0.063″	0.50 t	< 0.063″
5052-H32	Mill	0.375″	≥ 0.188″	≥ 0.094″	0.50 t	< 0.094″
5052-H32	Mill	0.500″	≥ 0.250″	≥ 0.125″	0.50 t	< 0.125″
6061-T6	Mill	0.032″	≥ 0.032″	≥ 0.016″	1.00 t	< 0.016″
6061-T6	Mill	0.040″	≥ 0.032″	≥ 0.016″	0.80 t	< 0.016″
6061-T6	Mill	0.050″	≥ 0.032″	≥ 0.016″	0.64 t	< 0.016″
6061-T6	Mill	0.063″	≥ 0.032″	≥ 0.016″	0.51 t	< 0.016″
6061-T6	Mill	0.090″	≥ 0.045″	≥ 0.022″	0.50 t	< 0.022″
6061-T6	Mill	0.100″	≥ 0.050″	≥ 0.025″	0.50 t	< 0.025″
6061-T6	Mill	0.125″	≥ 0.063″	≥ 0.031″	0.50 t	< 0.031″
6061-T6	Mill	0.188″	≥ 0.094″	≥ 0.047″	0.50 t	< 0.047″
6061-T6	Mill	0.250″	≥ 0.125″	≥ 0.063″	0.50 t	< 0.063″
6061-T6	Mill	0.375″	≥ 0.188″	≥ 0.094″	0.50 t	< 0.094″
6061-T6	Mill	0.500″	≥ 0.250″	≥ 0.125″	0.50 t	< 0.125″
6061-T6	Mill	0.625″	≥ 0.375″	≥ 0.188″	0.60 t	< 0.188″
6061-T6	Mill	0.750″	≥ 0.375″	≥ 0.188″	0.50 t	< 0.188″
7075-T6	Mill	0.080″	≥ 0.040″	≥ 0.020″	0.50 t	< 0.020″
7075-T6	Mill	0.100″	≥ 0.050″	≥ 0.025″	0.50 t	< 0.025″
7075-T6	Mill	0.125″	≥ 0.063″	≥ 0.031″	0.50 t	< 0.031″
7075-T6	Mill	0.160″	≥ 0.080″	≥ 0.040″	0.50 t	< 0.040″
7075-T6	Mill	0.190″	≥ 0.095″	≥ 0.048″	0.50 t	< 0.048″
7075-T6	Mill	0.250″	≥ 0.125″	≥ 0.063″	0.50 t	< 0.063″
7075-T6	Mill	0.375″	≥ 0.188″	≥ 0.094″	0.50 t	< 0.094″
7075-T6	Mill	0.500″	≥ 0.250″	≥ 0.125″	0.50 t	< 0.125″
7075-T6	Mill	0.750″	≥ 0.375″	≥ 0.188″	0.50 t	< 0.188″
7075-T6	Mill	1.000″	≥ 0.500″	≥ 0.250″	0.50 t	< 0.250″
A1008 cold rolled	CR Mill	0.024″	≥ 0.020″	≥ 0.010″	0.83 t	< 0.010″
A1008 cold rolled	CR Mill	0.030″	≥ 0.020″	≥ 0.010″	0.67 t	< 0.010″
A1008 cold rolled	CR Mill	0.036″	≥ 0.020″	≥ 0.010″	0.56 t	< 0.010″
A1008 cold rolled	CR Mill	0.048″	≥ 0.024″	≥ 0.012″	0.50 t	< 0.012″
A1008 cold rolled	CR Mill	0.060″	≥ 0.030″	≥ 0.015″	0.50 t	< 0.015″
A1008 cold rolled	CR Mill	0.075″	≥ 0.037″	≥ 0.019″	0.49 t	< 0.019″
A1008 cold rolled	CR Mill	0.090″	≥ 0.045″	≥ 0.022″	0.50 t	< 0.022″
A1008 cold rolled	CR Mill	0.100″	≥ 0.050″	≥ 0.025″	0.50 t	< 0.025″
A1008 cold rolled	CR Mill	0.120″	≥ 0.060″	≥ 0.030″	0.50 t	< 0.030″
A1008 cold rolled	CR Mill	0.135″	≥ 0.068″	≥ 0.034″	0.50 t	< 0.034″
A1008 electro-galvanized	Electro-Galv	0.024″	≥ 0.020″	≥ 0.010″	0.83 t	< 0.010″
A1008 electro-galvanized	Electro-Galv	0.048″	≥ 0.024″	≥ 0.012″	0.50 t	< 0.012″
A1008 electro-galvanized	Electro-Galv	0.060″	≥ 0.030″	≥ 0.015″	0.50 t	< 0.015″
A1008 electro-galvanized	Electro-Galv	0.075″	≥ 0.037″	≥ 0.019″	0.49 t	< 0.019″
A36 HR pickled & oiled	P&O	0.060″	≥ 0.030″	≥ 0.015″	0.50 t	< 0.015″
A36 HR pickled & oiled	P&O	0.075″	≥ 0.037″	≥ 0.019″	0.49 t	< 0.019″
A36 HR pickled & oiled	P&O	0.100″	≥ 0.050″	≥ 0.025″	0.50 t	< 0.025″
A36 HR pickled & oiled	P&O	0.120″	≥ 0.060″	≥ 0.030″	0.50 t	< 0.030″
A36 HR pickled & oiled	P&O	0.135″	≥ 0.068″	≥ 0.034″	0.50 t	< 0.034″
A36 HR pickled & oiled	P&O	0.188″	≥ 0.094″	≥ 0.047″	0.50 t	< 0.047″
A36 HR pickled & oiled	P&O	0.250″	≥ 0.125″	≥ 0.063″	0.50 t	< 0.063″
A36 HR pickled & oiled	P&O	0.375″	≥ 0.188″	≥ 0.094″	0.50 t	< 0.094″
A36 HR pickled & oiled	P&O	0.500″	≥ 0.250″	≥ 0.125″	0.50 t	< 0.125″
A36 mill finish	Mill Scale	0.060″	≥ 0.030″	≥ 0.015″	0.50 t	< 0.015″
A36 mill finish	Mill Scale	0.075″	≥ 0.037″	≥ 0.019″	0.49 t	< 0.019″
A36 mill finish	Mill Scale	0.100″	≥ 0.050″	≥ 0.025″	0.50 t	< 0.025″
A36 mill finish	Mill Scale	0.120″	≥ 0.060″	≥ 0.030″	0.50 t	< 0.030″
A36 mill finish	Mill Scale	0.135″	≥ 0.068″	≥ 0.034″	0.50 t	< 0.034″
A36 mill finish	Mill Scale	0.188″	≥ 0.094″	≥ 0.047″	0.50 t	< 0.047″
A36 mill finish	Mill Scale	0.250″	≥ 0.125″	≥ 0.063″	0.50 t	< 0.063″
A36 mill finish	Mill Scale	0.313″	≥ 0.157″	≥ 0.078″	0.50 t	< 0.078″
A36 mill finish	Mill Scale	0.375″	≥ 0.188″	≥ 0.094″	0.50 t	< 0.094″
A36 mill finish	Mill Scale	0.500″	≥ 0.250″	≥ 0.125″	0.50 t	< 0.125″
A36 mill finish	Mill Scale	0.625″	≥ 0.625″	≥ 0.313″	1.00 t	< 0.313″
A36 mill finish	Mill Scale	0.750″	≥ 0.750″	≥ 0.375″	1.00 t	< 0.375″
AR500	Mill	0.250″	≥ 0.125″	≥ 0.063″	0.50 t	< 0.063″
AR500	Mill	0.375″	≥ 0.188″	≥ 0.094″	0.50 t	< 0.094″
AR500	Mill	0.500″	≥ 0.250″	≥ 0.125″	0.50 t	< 0.125″
G90 galvanized	Hot-Dip Galv	0.024″	≥ 0.020″	≥ 0.010″	0.83 t	< 0.010″
G90 galvanized	Hot-Dip Galv	0.048″	≥ 0.024″	≥ 0.012″	0.50 t	< 0.012″
G90 galvanized	Hot-Dip Galv	0.060″	≥ 0.030″	≥ 0.015″	0.50 t	< 0.015″
G90 galvanized	Hot-Dip Galv	0.135″	≥ 0.068″	≥ 0.034″	0.50 t	< 0.034″
HSLAS Grade 50	Mill	0.188″	≥ 0.094″	≥ 0.047″	0.50 t	< 0.047″
HSLAS Grade 50	Mill	0.250″	≥ 0.125″	≥ 0.063″	0.50 t	< 0.063″
HSLAS Grade 50	Mill	0.313″	≥ 0.157″	≥ 0.078″	0.50 t	< 0.078″

Laser cut Cut — may taper Laser marked Min recommended Min hole size AluminumCarbon & alloy steelStainless steel

How to read it

Two limits. Three outcomes.

Every stock record has two numbers — the same two you see on each material page as Min Recommended Hole Size and Min Hole Size.

Pick a grade and the chart shades its three zones. Above the solid line the hole cuts clean. Between the solid and dashed lines it still cuts, but the wall can taper or roughen. Below the dashed line the laser cannot cut it, so it is marked instead.

The pattern is consistent: the recommended size is about half the thickness, never below 0.020″, and the minimum is half the recommended, never below 0.010″. Thin 6061-T6 holds a 0.032″ floor, and A36 mill-finish plate at 0.625″ and up steps to a full thickness. The chart and table show the exact value for every record, so use those rather than the rule of thumb.

01 / ≥ recommended

Laser cut

Clean, round hole at the drawn size. Design here wherever you can, especially for hardware, fasteners and anything that has to fit.

02 / minimum to recommended

Cut — may taper

The laser cuts through, but the hole can be slightly tapered or rough-walled. Fine for vents, lightening and cosmetic holes; call out precision fits separately on the drawing.

03 / below minimum

Laser marked

Too small to pierce and cut cleanly at that thickness. Our quote system converts the hole to a marked center automatically — the surface is etched, not cut through.

Below the minimum

We mark it. You drill it.

When a hole in your file is below the minimum, the quote app flags it — "hole is too small to cut — it will be marked instead" — and etches its center on the part. That mark is an accurate drill location, so small holes can still be made to size after cutting.

If you want that on purpose, say so on the drawing:

Example drawing noteLASER MARK CENTER ONLY.
DRILL Ø[FINAL DIAMETER] THRU BY CUSTOMER.
[QTY] PLACES.

Why the laser has a minimum at all — the pierce and the lead-in need room inside the hole — is covered in the minimum laser-cut hole size guide.

Holes sized? Send the file.

01 / GuideWhy there is a minimumThe pierce, the lead-in, and planning marked centers for drilling.Read the guide → 02 / CatalogSheet metal materialsEvery stocked gauge with bend, laser and hardware specs.Browse the catalog → 03 / QuoteUpload a partSmall holes are checked automatically when you quote.Get a quote →