Values are rule-of-thumb for automotive chassis wiring with typical insulation. For continuous loads, use 80% of rating. For long runs, consider voltage drop.
Minimum Inside Bend Radius (Air Bend – Starting Points)
Units: Thickness (in), Min Inside Radius (in)
Material
Thickness (in)
Min Inside Radius (in)
Mild Steel
0.060
0.060
Mild Steel
0.120
0.120
Aluminum 5052
0.063
0.050
Aluminum 6061-T6
0.063
0.094
Stainless 304
0.060
0.090
Tighter bends may crack or distort, especially for 6061-T6 and stainless. Use proper tooling; consider anneal or larger radius for cosmetic parts.
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Gauge,Steel (in),Steel (mm),Aluminum (in),Aluminum (mm)
20,0.036,0.91,0.032,0.81
18,0.048,1.22,0.040,1.02
16,0.060,1.52,0.050,1.27
14,0.075,1.90,0.064,1.63
12,0.105,2.67,0.081,2.06
10,0.135,3.43,0.102,2.59