{"id":2808,"date":"2026-11-06T11:42:05","date_gmt":"2026-11-06T03:42:05","guid":{"rendered":"https:\/\/skypumold.com\/inside-corners-milled-parts-radius-relief\/"},"modified":"2026-11-09T09:51:52","modified_gmt":"2026-11-09T01:51:52","slug":"inside-corners-milled-parts-radius-relief","status":"publish","type":"post","link":"https:\/\/skypumold.com\/ru\/inside-corners-milled-parts-radius-relief\/","title":{"rendered":"Inside Corner Radius on Milled Parts: How to Specify It"},"content":{"rendered":"<p>A milled inside corner always has a radius, because the cutter is round. The drawing should say how large that radius may be, whether a corner relief is allowed where a square part has to fit, and which few corners really need wire EDM or sinker EDM. This article explains how to choose the radius, when to use a relief, and how to state it clearly on your drawing.<\/p>\n<figure><img decoding=\"async\" src=\"https:\/\/skypumold.com\/wp-content\/uploads\/2026\/11\/skypu-c-shaped-bracket-stepped-edge-v3.jpg\" alt=\"C-shaped bracket with square inside corners machined by SkyPu\" \/><figcaption>A C-shaped bracket. Each arm meets the bar at an inside corner, and the drawing has to say what radius is allowed there.<\/figcaption><\/figure>\n<h2>Why Milled Inside Corners Are Always Round<\/h2>\n<p>An end mill cuts with its side, and its side is a circle. Where two milled walls meet, the corner takes the radius of the cutter: a 6 mm end mill leaves about 3 mm, a 2 mm end mill about 1 mm. Smaller radii need smaller cutters, which are slower, less rigid and cannot reach as deep, so the corner radius directly affects machining time and cost.<\/p>\n<p>Three kinds of inside corner are specified differently:<\/p>\n<ul>\n<li><strong>Vertical corners<\/strong>, where two side walls meet. Their radius comes from the cutter diameter.<\/li>\n<li><strong>Floor corners<\/strong>, where a wall meets the floor of a step or pocket. With a flat end mill they can be nearly sharp.<\/li>\n<li><strong>Through corners<\/strong> of slots or openings that go right through the part. These can be milled with a radius or cut by wire EDM with a much smaller one.<\/li>\n<\/ul>\n<h2>Choosing the Corner Radius<\/h2>\n<p>If nothing square has to sit in the corner, a generous radius is the cheapest and strongest option. Common CNC design guidance suggests:<\/p>\n<ul>\n<li><strong>At least one third of the wall depth.<\/strong> Hubs gives the example of a 12 mm deep cavity with a radius of 5 mm or more, which lets an 8 mm cutter do the work (<a href=\"https:\/\/www.hubs.com\/knowledge-base\/reducing-cnc-machining-costs-13-design-tips\/\" target=\"_blank\" rel=\"noopener\">Hubs<\/a>).<\/li>\n<li><strong>Slightly larger than the cutter radius,<\/strong> so the tool moves through the corner in an arc instead of being heavily loaded.<\/li>\n<li><strong>One radius for all inside corners<\/strong> where possible, to avoid extra tools.<\/li>\n<li><strong>Small or no floor radii,<\/strong> such as 0.5 mm or 1 mm, unless you need them for strength (<a href=\"https:\/\/www.hubs.com\/knowledge-base\/reducing-cnc-machining-costs-13-design-tips\/\" target=\"_blank\" rel=\"noopener\">Hubs<\/a>).<\/li>\n<\/ul>\n<p>On parts hardened after machining, a radius at the root of a step also reduces the risk of cracking, so it often helps the part as well as the cost.<\/p>\n<figure><img decoding=\"async\" src=\"https:\/\/skypumold.com\/wp-content\/uploads\/2026\/11\/skypu-stepped-plate-end-tabs-hole-row-v2.jpg\" alt=\"Stepped plate with end tabs and radiused inside corners machined by SkyPu\" \/><figcaption>A stepped plate with end tabs. The small radii at the inside corners are normal for milled corners.<\/figcaption><\/figure>\n<h2>When a Square Part Has to Fit: Corner Reliefs<\/h2>\n<p>If a corner must accept a part with sharp outer corners, such as a ground insert or a block that sits against both walls, a milled radius stops it from seating. The usual solution is a <strong>corner relief<\/strong> that removes material beyond the corner:<\/p>\n<ul>\n<li><strong>T-bone relief:<\/strong> the cutter goes past the corner along one wall, keeping the other wall clean. It only needs to extend by at least one cutter radius (<a href=\"https:\/\/get-it-made.co.uk\/resources\/machining-square-corners-with-cnc-milling\" target=\"_blank\" rel=\"noopener\">Get It Made<\/a>).<\/li>\n<li><strong>Dog-bone relief:<\/strong> the cutter goes diagonally into the corner and clears both walls. An offset version removes less material than a circle centred on the corner (<a href=\"https:\/\/get-it-made.co.uk\/resources\/machining-square-corners-with-cnc-milling\" target=\"_blank\" rel=\"noopener\">Get It Made<\/a>).<\/li>\n<li><strong>Undercut at a step:<\/strong> a small groove at the root lets a part sit flat on the floor and against the wall.<\/li>\n<\/ul>\n<p>State the largest relief you can accept, or mark the relief as allowed, and check that it does not break into a hole or a thin wall.<\/p>\n<h2>When the Corner Must Really Be Sharp: Wire EDM and Sinker EDM<\/h2>\n<ul>\n<li><strong>\u041f\u0440\u043e\u0432\u043e\u043b\u043e\u0447\u043d\u0430\u044f \u044d\u043b\u0435\u043a\u0442\u0440\u043e\u044d\u0440\u043e\u0437\u0438\u044f<\/strong> cuts features that go right through the part. The smallest inside radius is roughly the wire radius plus the discharge gap; PCBWay gives the example of a 0.2 mm wire producing about 0.13 mm, and notes that a zero radius cannot be made (<a href=\"https:\/\/www.pcbway.com\/blog\/CNC_Machining\/Electrical_Discharge_Machining_EDM_Process_Types_Technical_Guide_3f35da5a.html\" target=\"_blank\" rel=\"noopener\">PCBWay<\/a>). See <a href=\"https:\/\/skypumold.com\/ru\/wire-edm-punches-die-inserts\/\">wire EDM for punches and die inserts<\/a>.<\/li>\n<li><strong>Sinker EDM<\/strong> makes small corners in blind features where a wire cannot pass. See <a href=\"https:\/\/skypumold.com\/ru\/sinker-edm-mold-die-components\/\">sinker EDM for mold and die components<\/a>.<\/li>\n<\/ul>\n<p>EDM adds an operation, so mill the corners with a normal radius and mark only the functional ones with a maximum radius.<\/p>\n<figure><img decoding=\"async\" src=\"https:\/\/skypumold.com\/wp-content\/uploads\/2026\/11\/skypu-slotted-block-four-counterbored-holes.jpg\" alt=\"Split block with a stepped slot and square inside corners machined by SkyPu\" \/><figcaption>A split block with a stepped slot. The inside corners of the step decide whether a mating part can sit flat.<\/figcaption><\/figure>\n<h2>Outside Edges Are a Separate Question<\/h2>\n<p>Outside edges are normally deburred or given a small chamfer. ISO 13715 gives a way to state the condition of edges whose shape is not drawn: a minus value means material must be removed (such as a chamfer on an outside edge), and a plus value means extra material is allowed (such as a small fillet in an inside corner) (<a href=\"https:\/\/www.modulusmetal.com\/iso-13715-technical-product-documentation-edges-of-undefined-shape-indication-and-dimensioning\" target=\"_blank\" rel=\"noopener\">Modulus Metal, ISO 13715 overview<\/a>). If you use a general edge note, make sure it also covers inside corners.<\/p>\n<h2>How to Show Inside Corners on the Drawing<\/h2>\n<table>\n<thead>\n<tr>\n<th>Situation<\/th>\n<th>Example note or callout<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>General rule for milled corners<\/td>\n<td>UNLESS OTHERWISE SPECIFIED, INSIDE CORNERS R1 MAX<\/td>\n<\/tr>\n<tr>\n<td>Radius not critical<\/td>\n<td>INSIDE CORNER RADII AT SUPPLIER&#8217;S OPTION, R5 MAX<\/td>\n<\/tr>\n<tr>\n<td>Corner that must take a square part<\/td>\n<td>CORNER RELIEF ALLOWED, \u00d84 MAX<\/td>\n<\/tr>\n<tr>\n<td>Step where a part must sit flat on both faces<\/td>\n<td>UNDERCUT AT ROOT OF STEP ALLOWED, 0.5 \u00d7 0.5 MAX<\/td>\n<\/tr>\n<tr>\n<td>Functional sharp corner in a through feature<\/td>\n<td>R0.15 MAX (WIRE EDM)<\/td>\n<\/tr>\n<tr>\n<td>Outside edges<\/td>\n<td>BREAK ALL SHARP EDGES 0.2\u20130.5, or an ISO 13715 edge note<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>These values are examples. Say whether a value is a maximum or a nominal size: &#8220;R1 MAX&#8221; allows any radius up to 1 mm, while &#8220;R1&#8221; with the general tolerance is nominal. If you send only a 3D model with sharp inside corners and no note, the radius is undefined, so model it or add a note.<\/p>\n<h2>Checklist Before You Send the Drawing<\/h2>\n<ul>\n<li>A general note for inside corner radii, stating maximum or nominal.<\/li>\n<li>Vertical radii at least about one third of the wall depth where possible, and the same radius on most corners.<\/li>\n<li>A relief shown or allowed wherever a square part must fit.<\/li>\n<li>Only truly functional corners marked with a small maximum radius for EDM.<\/li>\n<li>A separate note for outside edges.<\/li>\n<\/ul>\n<figure><img decoding=\"async\" src=\"https:\/\/skypumold.com\/wp-content\/uploads\/2026\/11\/skypu-stepped-block-tapped-hole-angled-corner-v2.jpg\" alt=\"Stepped block with a tapped hole and an angled corner machined by SkyPu\" \/><figcaption>A stepped block with a tapped hole and an angled corner.<\/figcaption><\/figure>\n<h2>How We Machine Steps, Slots and Inside Corners<\/h2>\n<p>At SkyPu, we make <a href=\"\/ru\/cnc-precision-machining\/\">CNC machined parts<\/a> \u0438 <a href=\"\/ru\/stamping-die-components\/\">stamping die components<\/a> to customer drawings, including fixture blocks, brackets, stepped plates and die plates. Steps, slots and pockets are milled on our 8 CNC machining centers, and openings that need small inside radii are cut on our 18 wire EDM machines, including Sodick low-speed wire EDM. Critical dimensions are checked with Nikon and TESA inspection equipment, and a dimensional report can be supplied on request. Selected features can be held to approximately \u00b10.002 mm. You can see examples in our <a href=\"\/ru\/product-category\/%d1%84%d1%80%d0%b5%d0%b7%d0%b5%d1%80%d0%be%d0%b2%d0%b0%d0%bd%d0%b8%d0%b5-%d1%81-%d1%87%d0%bf%d1%83\/\">CNC milling product cases<\/a> \u0438 <a href=\"\/ru\/product-category\/stamping-tooling\/\">stamping tooling product cases<\/a>. If a corner on your drawing would be cheaper with a different radius or a relief, we will point it out when we quote.<\/p>\n<h2>\u0427\u0430\u0441\u0442\u043e \u0437\u0430\u0434\u0430\u0432\u0430\u0435\u043c\u044b\u0435 \u0432\u043e\u043f\u0440\u043e\u0441\u044b<\/h2>\n<h3>Can you mill a perfectly sharp inside corner?<\/h3>\n<p>No. A milled vertical inside corner always has a radius at least equal to the cutter radius. Use a corner relief for square mating parts, or wire EDM or sinker EDM for very small radii.<\/p>\n<h3>What inside corner radius should I put on my drawing?<\/h3>\n<p>The largest your design allows: typically at least one third of the wall depth, slightly larger than the cutter radius, and the same on all corners where possible.<\/p>\n<h3>How small can a wire EDM inside corner be?<\/h3>\n<p>Roughly the wire radius plus the discharge gap, for example about 0.13 mm with a 0.2 mm wire. Give a maximum radius instead of a sharp corner.<\/p>\n<p><strong>Need fixture blocks, brackets or stepped plates made to drawing? <a href=\"\/ru\/quote-request\/\">Send your drawings<\/a> with material, quantity and any critical corners marked, and we will review it and reply with a price and lead time.<\/strong><\/p>\n<h2>Sources<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.hubs.com\/knowledge-base\/reducing-cnc-machining-costs-13-design-tips\/\" target=\"_blank\" rel=\"noopener\">Hubs: Reducing CNC machining costs, design tips (internal corner radii and cavity depth)<\/a><\/li>\n<li><a href=\"https:\/\/get-it-made.co.uk\/resources\/machining-square-corners-with-cnc-milling\" target=\"_blank\" rel=\"noopener\">Get It Made: Machining square corners with CNC milling (fillets, dog-bone and T-bone reliefs)<\/a><\/li>\n<li><a href=\"https:\/\/www.pcbway.com\/blog\/CNC_Machining\/Electrical_Discharge_Machining_EDM_Process_Types_Technical_Guide_3f35da5a.html\" target=\"_blank\" rel=\"noopener\">PCBWay: EDM design guidelines (wire EDM minimum inside corner radius)<\/a><\/li>\n<li><a href=\"https:\/\/en.wikipedia.org\/wiki\/Rule-based_DFM_analysis_for_electric_discharge_machining\" target=\"_blank\" rel=\"noopener\">Wikipedia: Rule-based DFM analysis for electric discharge machining<\/a><\/li>\n<li><a href=\"https:\/\/www.modulusmetal.com\/iso-13715-technical-product-documentation-edges-of-undefined-shape-indication-and-dimensioning\" target=\"_blank\" rel=\"noopener\">Modulus Metal: ISO 13715, edges of undefined shape, indication and dimensioning<\/a><\/li>\n<\/ul>","protected":false},"excerpt":{"rendered":"<p>Why milled inside corners are always round, how to choose the corner radius, when to use dog-bone or T-bone reliefs, when a corner needs wire EDM or sinker EDM, and example drawing notes.<\/p>","protected":false},"author":1,"featured_media":3114,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[18],"tags":[],"class_list":["post-2808","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-cnc-machining"],"blocksy_meta":{"styles_descriptor":{"styles":{"desktop":"","tablet":"","mobile":""},"google_fonts":[],"version":8}},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Inside Corner Radius on Milled Parts: How to Specify It | SkyPu<\/title>\n<meta name=\"description\" content=\"Milled inside corners are always round. 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