Standards & Thickness
Gauge systems explained
Decode the major gauge systems—American Wire Gauge (AWG), Birmingham Wire Gauge (BWG), and sheet metal gauge— and translate gauge numbers to millimeters and inches without guesswork.
Origins and differences
Gauge scales were born from manufacturing steps, not from a clean metric or imperial formula. Each system defines its own zero point and step size, so numbers do not align across systems.
- AWG: North American wire diameter system, logarithmic step sizes; used for electrical conductors.
- BWG: Legacy steel wire gauge, thicker than equivalent AWG numbers; still seen in needles and tubing.
- Sheet metal gauge: Varies by material (steel, aluminum) with separate charts and no single formula.
Quick lookup examples
AWG 12 wire: about 2.05 mm diameter (0.0808 in)
AWG 24 wire: about 0.51 mm diameter (0.0201 in)
BWG 12: about 2.77 mm (0.109 in); thicker than AWG 12
Sheet steel 14 ga: about 1.90 mm (0.0747 in), but aluminum 14 ga differs (~1.63 mm)
Always cite the material and gauge system. For procurement, add the metric thickness in parentheses.
Conversion and specification guidance
Gauge tables are not linear; do not extrapolate. Use published charts and specify tolerance separately. Provide dual units to keep global teams aligned.
Material-dependent charts
Sheet metal gauge differs between steel and aluminum. Use the correct chart to avoid over- or under-thickness.
State both gauge and thickness
Example: "14 ga steel (approx 1.90 mm) per ASTM A653, tolerance per table A2." This avoids ambiguity for international teams.
Avoid rounding chains
Do not convert gauge to inches, then to mm, then back. Keep a single source thickness and reference it in both units.
Where gauge confusion causes issues
- Electrical: choosing AWG vs stranded equivalents; ampacity depends on conductor size and insulation rating.
- Medical needles: BWG sizes differ from AWG; wrong gauge changes flow rate and strength.
- Sheet fabrication: quoting steel gauge for aluminum leads to thinner parts than expected.
- Tubing: BWG wall thickness alters pressure rating; mixing standards risks burst or collapse.
Documentation checklist
Cite the gauge system (AWG, BWG, or material-specific sheet gauge).
Include exact thickness in mm and inches to three or four decimals.
List tolerance separately; do not rely on gauge alone for QA.
Link to the source chart or standard revision to keep teams aligned.
Frequently Asked Questions
Convert and verify thickness
Use the mm to inches converter to pair gauge callouts with exact thickness values, then share both units in your drawings and work orders.