In part two of Tab and Slots we talk about Tab and Slot Clearances – breaking down everything you need to know to get the perfect fit for your designs.

In this episode we cover tolerances, material thickness, and how different materials like aluminum and steel impact your fit. We designed a variety of parts, tested different tolerances, and examined key factors like dross, deburring, and laser cut precision. Starting with zero tolerance, we progressively increase the tolerance to show how fit changes with different materials and thicknesses. We also break down mill tolerances, laser cutting precision, and why a little wiggle room can make all the difference—especially for complex assemblies with multiple bends.

For best results, check out our recommendations on our website and consider ordering a few test pieces before finalizing your design.