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What usually matters more than absolute tolerances is relative tolerance, aka ppm. 100 micron / 4 thou tolerance can be achieved with hand tools and a bit of patience on the benchtop scale, say a 4" part. That's about 1000 ppm, or 0.1%. If I gave you a meter stick, you could probably eyeball marking something +/- 1mm.

Getting the same finish on a 120"/3m coil is 33 ppm. 100 ppm / 0.01% for any operation or process tends to be where things start to get really challenging. Deflection goes up by the length cubed, so increasing the size of all the tooling relative to the tolerance gets really challenging really fast.




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