Uploaded July 2026 | Updated September 2026, 1 day ago
In this lesson we answer a common design question about how we determine minimum hole sizes and minimum bridge distances listed in our guidelines.
Using material specific test cards for different thicknesses machine types and processes we demonstrate how hole size, bridge width, heat input, tool diameter and material behavior all affect whether a feature cuts cleanly or fails.
In this episode you will learn how to:
• Understand why minimum hole sizes change with material and thickness
• See how bridge width affects heat buildup warping and part stability
• Recognize how thicker materials absorb heat differently than thin sheet
• Learn why some small holes fail due to laser limits or tool diameter
• Understand how router bit size controls minimum feature size in plastics
• See how internal testing sets you up for successful parts on the first try
⏰ Timestamps ⏰
00:00: Introduction to the question
00:45: Stainless steel examples, failures, and warping
01:13: Thicker material example, small holes, bridge burnout
01:43: CNC router example with ABS
02:10: Chatter, bending, and breakage
If you want your questions answered in a future episode drop them in the comments of the main lessons at sendcutsend.com education
Start your journey and turn your ideas into custom manufactured parts at sendcutsend.com/education
Want to rock the same gear as Jake? Grab your SendCutSend merch here: store.sendcutsend.com
Custom sheet metal manufacturing and processing. From prototype to large production runs, get sale and assembly ready custom parts shipped in as little as 2 days; No minimum quantities; free US shipping on orders over $39; made In the USA: bit.ly/4dwW6rU
Follow us on Instagram: instagram.com/sendcutsend
SendCutSend Education was filmed and edited by Keaton Bowlby.
In this lesson we answer a common design question about how we determine minimum hole sizes and minimum bridge distances listed in our guidelines.
Using material specific test cards for different thicknesses machine types and processes we demonstrate how hole size, bridge width, heat input, tool diameter and material behavior all affect whether a feature cuts cleanly or fails.
In this episode you will learn how to:
• Understand why minimum hole sizes change with material and thickness
• See how bridge width affects heat buildup warping and part stability
• Recognize how thicker materials absorb heat differently than thin sheet
• Learn why some small holes fail due to laser limits or tool diameter
• Understand how router bit size controls minimum feature size in plastics
• See how internal testing sets you up for successful parts on the first try
⏰ Timestamps ⏰
00:00: Introduction to the question
00:45: Stainless steel examples, failures, and warping
01:13: Thicker material example, small holes, bridge burnout
01:43: CNC router example with ABS
02:10: Chatter, bending, and breakage
If you want your questions answered in a future episode drop them in the comments of the main lessons at sendcutsend.com education
Start your journey and turn your ideas into custom manufactured parts at sendcutsend.com/education
Want to rock the same gear as Jake? Grab your SendCutSend merch here: store.sendcutsend.com
Custom sheet metal manufacturing and processing. From prototype to large production runs, get sale and assembly ready custom parts shipped in as little as 2 days; No minimum quantities; free US shipping on orders over $39; made In the USA: bit.ly/4dwW6rU
Follow us on Instagram: instagram.com/sendcutsend
SendCutSend Education was filmed and edited by Keaton Bowlby.
