Sheet Metal Gauges and Thickness Guide: Stainless Steel, Aluminum, Copper & Brass
When ordering sheet metal, one of the most confusing things to figure out is thickness. You’ll see terms like "16 gauge" or ".063-inch"—but what do they really mean? And why does 16 gauge vary depending on the type of metal?
Quick Answer: In sheet metal, gauge is a traditional way to measure thickness where a lower gauge number means thicker metal — but the exact thickness depends on the material. Decimal thickness is a precise measurement in inches and is consistent across all metals.
At Cut2SizeMetals.com, we want to make your buying experience easier. That starts with understanding the numbers. In this guide, we’ll explain the difference between gauge and decimal thickness, show how thickness standards vary by material, and give you the information you need to select the right sheet for your project.
Gauge vs. decimal thickness in sheet metal: What’s the difference?
In sheet metal, gauge is a traditional way to measure thickness, where a lower gauge number means thicker metal, but exact thickness varies by material. This means the same gauge number can correspond to slightly different actual thicknesses depending on the type of metal, because each metal type follows its own historical gauge standard. While 16-gauge materials can vary slightly between metals, these differences rarely impact most projects. Visit the product page to view the full specification chart for your metal type, and feel free to call us with any questions.
That’s why many professionals rely on decimal measurements (e.g., 0.060") in addition to gauge for accuracy. Decimal thickness is more precise, especially when working from engineering specs or CAD drawings.
A few key points:
- Lower gauge numbers = thicker and heavier metal (though exact thickness varies by material)
- Gauge standards are material-specific (aluminum, stainless steel, and copper each use their own charts)
- Decimal thickness is exact and listed on all Cut2SizeMetals product pages
Did you know:
Gauge numbers originated from the number of steps needed to produce a given thickness of wire in the 19th century. Over time, different industries adopted their own standards, which is why gauge numbers are not universal across all metals.
For example, copper and brass use the Brown & Sharpe (B&S) gauge system, which differs from the gauge system used for steel or aluminum. Tubing and some piping products may be specified using Birmingham Wire Gauge (BWG), which has its own conversion values. This means the same gauge number can represent very different actual thicknesses depending on the material and the standard.
At Cut2SizeMetals, we list copper and brass primarily by decimal thickness (and for copper, by its industry-standard ounces per square foot), with gauge values provided only as an approximate reference.
Note on tolerances:
Actual sheet thickness may vary slightly due to manufacturing tolerances, especially when comparing cold-rolled versus hot-rolled materials. For most gauges, standard tolerances are within ± 0.003″ to ± 0.005″ of the listed thickness. While this variation is negligible for many everyday projects, it can be significant for tight-tolerance applications or precision assemblies. When exact fits are critical—especially in engineering or mechanical usage—it's best to verify the actual thickness before fabrication.
Thickness ranges by material at Cut2SizeMetals.com
Once you understand how thickness is measured, it’s helpful to see what is available. Here's how the sheet metal we carry compares in terms of thickness range:
Stainless steel sheet gauge range
- Thickness range: 26 gauge (0.018") to 7 gauge (0.1874")
- Standard sheet sizes: 36” x 120” up to 60” x 120” (can be cut to size)
- Grades/Alloys: 304, 316, and 430
- Finishes: Mill, 2B, brushed, and #4 or #8 polished finishes
Note: The typical distinction between plate and sheet is that plate is 1/4 inch or thicker. However, Cut2SizeMetals offers both 3/16-inch plate and 7-gauge (3/16 inch) sheet. The plate has a rougher surface, while the sheet has a smooth finish. Visit Stainless Steel Plate >
Aluminum sheet gauge and thickness range
- Thickness range: 0.016" to 0.19" (typically listed in decimal form)
- Standard sheet sizes: 36” x 96” up to 72” x 144” (can be cut to size)
- Alloys available: 3003 and 6061 with mill finishes only
- For 0.25" (1/4") thick and above, visit our Aluminum Plate page >
Copper sheet gauge and thickness range
- Thickness range: 26 gauge (0.0216") to 11 gauge (0.125")
- Standard sheet sizes: 36" x 96" or 36" x 120", depending on thickness (can be custom cut)
- Alloy: C110 with mill finish only
- For 0.250" (1/4") thickness, visit our Copper Plate page >
A Note about Copper:
At Cut2SizeMetals, copper sheet is listed by its thickness in inches, but the industry standard for manufacturing is weight in ounces per square foot — a convention especially common in architectural and roofing applications. For example, “16 oz copper” is about 0.0216″ thick, and “24 oz copper” is about 0.0323″ thick.
We also provide an approximate Brown & Sharpe gauge for reference, though the gauge is a tertiary measure for copper and not an exact match. If your plans or specifications list copper by ounces per square foot or gauge, our team can help you translate that into the decimal thicknesses we sell. Contact our customer service team for assistance.
Brass sheet gauge and thickness range
- Thickness range: 0.020" to 0.125" (typically listed in decimal form)
- Standard sheet sizes: 36" x 96" (can be custom cut to any size)
- Grade and finish: 260 alloy with mill finish for general-purpose use
Note: Plate is generally considered 1/4 inch or thicker. We also offer 3/16-inch brass plate. Visit our Brass Plate page >
All product pages include gauge (when applicable) and decimal thickness, and we encourage you to review the "Specs Charts & Available Sizes" section for a full breakdown by material and thickness.
Don't see the thickness you need? Give us a call. We can often source special sizes or materials to meet your project requirements.
Visualizing sheet metal thickness with everyday items
What are some everyday items that match common sheet metal thicknesses? If you're having trouble picturing how thick a particular gauge or decimal measurement is, here are some everyday items for rough comparison. These are not exact matches, but they can provide a helpful frame of reference.
| Approx. Thickness (inches) | Item |
|---|---|
| 0.012” | Business card / Standard Playing Card |
| 0.014” | Photo Paper (Glossy) |
| 0.015” | Magazine Cover |
| 0.018” | Cereal Box (Chipboard) |
| 0.024” | 2 Stacked Standard Playing Cards |
| 0.030" | Credit Card |
| 0.034" | Standard Paperclip Wire |
| 0.053" | U.S. Dime |
| 0.059" | U.S. Penny |
| 0.069" | U.S. Quarter |
| 0.077” | U.S. Nickel |
| 0.085” | Standard House Key |
| 0.090” | 3 Stacked Credit Cards |
| 0.118" | 2 Stacked U.S. Pennies |
| 0.138” | 2 Stacked U.S. Quarters |
| 0.179” | 3 Stacked U.S. Pennies |
| 0.260” | Standard No. 2 Pencil (Diameter) |
| 0.307” | 4 Stacked Nickels |
Note: These comparisons are only meant to help visualize relative thickness. Always refer to decimal and gauge specs for exact requirements.
Choosing the right thickness for your project
Getting the thickness right is essential. Too thin, and your sheet might warp or dent; too thick, and it could be heavier or more challenging to fabricate.
Here are some things to consider:
- Need more strength? Choose a lower gauge (thicker metal).
- Minimizing weight? Go with a thin aluminum sheet.
- Planning to bend or machine it? Softer alloys or mid-range thicknesses are best.
- Want something easy to shape or decorative? Try thin copper or brass.
Not sure what’s right? Contact our team—we’re happy to help you find the ideal thickness and material for your project.
Custom sheet metal, cut to size and ready to ship
At Cut2SizeMetals.com, we make it easy to order exactly what you need. Choose your material, enter your custom dimensions, and we’ll precision-cut your order—no minimums, fast turnaround, and precise thickness specs on every product.
Ready to get started? Start your custom sheet metal order today.
Cut2Size Metals provides general properties and typical uses for the products we carry, however, the suitability of a material for any application or the manner of its use is the sole responsibility of the customer. If you have specific requirements for your application, we strongly suggest contacting us before purchasing. For specific questions or further assistance, feel free to call us at (812) 429-1634. We're here to help!
Sheet metal gauge & thickness FAQ
Quick answers to common questions about gauge systems, thickness measurement, and choosing the right sheet for your project.