Mil/Thou to Inch Converter
Convert mils to inches with our free online length converter.
Quick Answer
1 Mil/Thou = 0.001 inches
Formula: Mil/Thou × conversion factor = Inch
Use the calculator below for instant, accurate conversions.
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All conversion formulas on UnitsConverter.io have been verified against NIST (National Institute of Standards and Technology) guidelines and international SI standards. Our calculations are accurate to 10 decimal places for standard conversions and use arbitrary precision arithmetic for astronomical units.
Mil/Thou to Inch Calculator
How to Use the Mil/Thou to Inch Calculator:
- Enter the value you want to convert in the 'From' field (Mil/Thou).
- The converted value in Inch will appear automatically in the 'To' field.
- Use the dropdown menus to select different units within the Length category.
- Click the swap button (⇌) to reverse the conversion direction.
How to Convert Mil/Thou to Inch: Step-by-Step Guide
Converting Mil/Thou to Inch involves multiplying the value by a specific conversion factor, as shown in the formula below.
Formula:
1 Mil/Thou = 0.001 inchesExample Calculation:
Convert 10 mils: 10 × 0.001 = 0.01 inches
Disclaimer: For Reference Only
These conversion results are provided for informational purposes only. While we strive for accuracy, we make no guarantees regarding the precision of these results, especially for conversions involving extremely large or small numbers which may be subject to the inherent limitations of standard computer floating-point arithmetic.
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What is a Mil?
A mil (also called thou) is a unit of length in the imperial measurement system equal to one thousandth of an inch. The mathematical definition is:
1 mil = 0.001 inch = 1/1000 inch = 25.4 micrometers (μm) = 0.0254 millimeters
The mil is not a metric unit and should not be confused with the millimeter (mm), despite similar-sounding names. This confusion is one of the most common measurement errors in international manufacturing:
- 1 mil (imperial) = 0.0254 mm = 25.4 μm
- 1 millimeter (metric) = 39.37 mils = 1,000 μm
The mil exists as a natural subdivision of the inch, providing a convenient decimal-based measurement for very small imperial dimensions without resorting to awkward fractions like 1/1000″.
Mil vs. Thou: Regional Terminology
The terms "mil" and "thou" are completely interchangeable and refer to the exact same measurement:
- Mil: Predominant in American English, technical documentation, industry standards (ASTM, ANSI), and scientific contexts. The name derives from Latin "mille" (thousand).
- Thou: Common in British English shop-floor terminology, machining, and colloquial engineering speech. It's an abbreviated form of "thousandth" (of an inch).
Example usage:
- American engineer: "The coating should be 5 mils thick."
- British machinist: "Machine this to within 2 thou tolerance."
- Both mean the same thing: 0.005″ and 0.002″ respectively.
Decimal Imperial vs. Fractional Imperial
The mil represents a decimal approach to imperial measurement, contrasting with the traditional fractional approach:
Fractional imperial (traditional):
- 1/2″, 1/4″, 1/8″, 1/16″, 1/32″, 1/64″
- Awkward for very small measurements
- Difficult to add/subtract without common denominators
Decimal imperial (mils/thousandths):
- 0.500″ (500 mils), 0.250″ (250 mils), 0.125″ (125 mils)
- Easy arithmetic: 5 mils + 3 mils = 8 mils
- Natural compatibility with digital calipers and micrometers
Engineering drawings often show both: 0.250″ (1/4″) for clarity, but critical tolerances are always specified in decimal thousandths: ±0.005″ (±5 mils), never ±1/200″.
Mils in Wire Gauge Systems
American Wire Gauge (AWG) uses diameter in mils as the basis for its numbering system, though the relationship is logarithmic rather than linear:
| AWG Size | Diameter (mils) | Diameter (mm) | Common Use | |----------|----------------|---------------|------------| | 0000 (4/0) | 460 mil | 11.7 mm | Heavy power cables | | 00 (2/0) | 365 mil | 9.3 mm | Welding cable | | 10 AWG | 102 mil | 2.6 mm | Household 30A circuits | | 14 AWG | 64 mil | 1.6 mm | Household 15A circuits | | 18 AWG | 40 mil | 1.0 mm | Lamp cords, doorbells | | 22 AWG | 25 mil | 0.64 mm | Solid hookup wire | | 30 AWG | 10 mil | 0.25 mm | Wire-wrap wire | | 40 AWG | 3 mil | 0.08 mm | Magnet wire (coils) |
The AWG system was established in the 1850s based on the number of times wire was drawn through reducing dies, with each gauge step representing approximately a 20% reduction in diameter (factor of √2 for cross-sectional area).
The inch is a unit of length in the British imperial and United States customary systems of measurement. Since the international yard and pound agreement of 1959, one inch has been defined as exactly 2.54 centimeters. This makes the inch equal to 1/12 of a foot, 1/36 of a yard, and 25.4 millimeters precisely.
The inch is denoted by the symbol in or by a double prime mark ″ (e.g., 5″ means 5 inches). In engineering drawings and construction blueprints, dimensions are typically expressed in feet and inches (e.g., 5′-3″ means 5 feet, 3 inches).
Unlike the metric system with its consistent decimal relationships, the inch exists within a complex system where 12 inches make a foot, 3 feet make a yard, and 1,760 yards make a mile. This fractional system reflects the inch's origins in human-scale measurements rather than mathematical convenience.
Note: The Mil/Thou is part of the imperial/US customary system, primarily used in the US, UK, and Canada for everyday measurements. The Inch belongs to the imperial/US customary system.
History of the Mil/Thou and Inch
Ancient and Medieval Precision (Before 1700)
Before the Industrial Revolution, precision measurement was limited by available tools. Ancient civilizations measured small lengths using:
- Barleycorns: 1 inch = 3 barleycorns (still referenced in shoe sizing)
- Hair breadth: Approximately 1/48 of an inch (about 21 mils)
- Poppy seed: Medieval unit ≈ 1/72 inch (14 mils)
These natural standards were inconsistent but adequate for carpentry, masonry, and traditional crafts where tolerances of 1/16″ to 1/32″ were acceptable. Precision metalworking (locksmithing, clockmaking, weapon-smithing) relied on master craftsmen's skill and direct comparison to reference standards rather than numerical measurement.
The finest medieval measurements were in clock and instrument making, where tolerances approaching 1/100″ (10 mils) were occasionally achieved, but not reliably measured or documented.
Industrial Revolution and the Birth of Precision (1750-1850)
The transformation of manufacturing from craft to industry created an urgent need for precision measurement:
1775-1800: John Wilkinson's cylinder boring machine (1775) achieved tolerances within 1/20″ (50 mils) for steam engine cylinders—revolutionary at the time, enabling James Watt's efficient steam engines.
1800-1840: Interchangeable parts manufacturing emerged. Eli Whitney's 1798 contract to produce 10,000 muskets with interchangeable parts required consistent tolerances around 1/32″ (31 mils), though he struggled to achieve this consistently.
1840s: Joseph Whitworth revolutionized precision measurement:
- Invented the first practical micrometer (1840s), capable of measuring to 0.001″ (1 mil)
- Developed precision surface plates and scrapers
- Standardized screw threads with tolerances of a few thousandths
- Established the "thou" as the standard British precision unit
Whitworth's work meant that for the first time, machinists could reliably measure and verify work to within one thousandth of an inch, making the mil/thou a practical working unit rather than a theoretical ideal.
1850s: American System of Manufacturing (Colt, Robbins & Lawrence, Singer) adopted decimal measurements in thousandths for gauging and inspection, establishing "mils" in American technical vocabulary.
Standardization and Proliferation (1850-1920)
1860s-1880s: Development of precision measuring instruments:
- Vernier calipers graduated in thousandths
- Micrometer calipers (marketed by Brown & Sharpe from 1867)
- Dial indicators (from 1890s) showing 0.001″ divisions
1857: American Wire Gauge (AWG) standardized by J. R. Brown, using wire diameter in mils as the basis.
1880s-1900s: Paint and coating industries adopted mils for dry film thickness:
- Paint manufacturers specified coverage rates based on mils of dry film
- Wet film thickness gauges calibrated in mils
- Quality standards (e.g., U.S. Navy specifications) required minimum coating thickness in mils
1900-1920: Sheet metal gauges proliferated (ironically, these use arbitrary numbering systems, but actual thickness is specified in decimal inches/mils):
- Manufacturer's Standard Gauge (MSG) for steel
- Birmingham Wire Gauge (BWG)
- Confusion from multiple gauge systems led to increasing use of direct mil specifications
1916: SAE (Society of Automotive Engineers) founded, establishing thousands of specifications with tolerances in thousandths of an inch for automotive parts.
Electronics Age and Micro-Precision (1920-1980)
1930s-1940s: Electronics manufacturing adopted mils for:
- Wire insulation thickness (enamel on magnet wire: 0.5-2 mils)
- Capacitor dielectric thickness
- Vacuum tube electrode spacing
1943: Printed Circuit Board (PCB) invention (Paul Eisler, 1943; mass production 1950s):
- Copper foil thickness: 1.4 mils (1 oz/ft²), 2.8 mils (2 oz/ft²)
- Trace width: typically 5-15 mils for signal traces
- Spacing between traces: 5-8 mils minimum in early designs
- PCB substrate thickness: 62 mils (1.57 mm) became standard
1950s-1960s: Plastic film industry standardized thickness in mils:
- Polyethylene film (bags, wrap): 0.5-6 mils
- Polyester film (Mylar): 0.5-10 mils
- Vinyl flooring underlayment: 6-20 mils
1960s: Integrated circuit (IC) manufacturing pushed precision far beyond mils:
- Early transistors: features measured in tens of mils
- By 1970: features approaching 100 microinches (0.1 mil)
- The mil remained relevant for IC package dimensions, lead spacing, and encapsulation thickness
1975: ANSI/ASTM standards codified mil-based specifications for coating thickness, plastic film, and adhesive tape across dozens of industries.
Modern Era and Metrication Resistance (1980-Present)
1980s-1990s: Global metrication movement:
- Britain officially metricated in 1965-1995, but "thou" persisted in machine shops
- U.S. industries largely resisted metrication in favor of established decimal-inch (mil) systems
- Aerospace, defense, and automotive industries retained imperial specs due to:
- Enormous legacy of existing designs, tooling, and parts libraries
- Cost of converting decades of technical documentation
- Risk of conversion errors (Mars Climate Orbiter lost in 1999 due to metric/imperial confusion)
1990s-2000s: PCB design and microelectronics:
- PCB CAD software (OrCAD, Altium, Eagle) defaulted to mil grid spacing (5 mil, 10 mil, 25 mil grids)
- Modern PCB fabrication: 3-4 mil traces/spaces achievable in standard processes
- Advanced processes: sub-mil features (0.5 mil), but package and board dimensions still in mils
2000s-Present: Hybrid metric/imperial usage:
- American manufacturing: Part dimensions often in inches/mils, tolerances in mils
- International suppliers: Provide both metric and mil equivalents
- 3D printing: Software often accepts both (mil settings for layer height, nozzle diameter)
- Coating industry: Paint thickness gauges typically show both mils and microns
Present day: The mil remains dominant in:
- American PCB and electronics manufacturing
- U.S. aerospace and defense (military specifications)
- Coating and painting (ASTM standards)
- Plastic film and flexible packaging
- American Wire Gauge system
- Machining tolerances in U.S. shops
The inch has one of the longest continuous histories of any modern measurement unit, with roots stretching back over two millennia.
Ancient Origins: The Roman "uncia" (meaning one-twelfth) represented 1/12 of a Roman foot, similar to our modern inch. When the Romans occupied Britain, they brought this measurement system with them, establishing a tradition that would last far beyond their empire.
Medieval Definitions: Throughout the Middle Ages, various rulers attempted to standardize the inch using body-based measurements. King Edward I of England ordered in 1305 that an inch should equal the length of three barleycorns (grains of barley) laid end to end. King Edward II formalized this in 1324, making it English law. Other definitions included the width of a man's thumb at the base of the nail.
Regional Variations: Before standardization, different regions maintained slightly different inch measurements. The Tower inch, Merchant's inch, and Cloth inch all differed slightly, causing confusion in trade and construction. The French pouce (thumb) was approximately 1.066 English inches.
1959 International Agreement: The modern inch was defined by the international yard and pound agreement signed by the United States, United Kingdom, Canada, Australia, New Zealand, and South Africa. They agreed that 1 yard equals exactly 0.9144 meters, making 1 inch exactly 2.54 centimeters. This ended centuries of slight variations and created perfect mathematical alignment between imperial and metric systems.
US Survey Inch: For a time, the US maintained two slightly different inches—the international inch (2.54 cm exactly) and the US survey inch (2.540005080010160020 cm, based on the Mendenhall Order of 1893). As of January 1, 2023, the US officially retired the survey inch, making all American measurements use the international inch exclusively.
Common Uses and Applications: mils vs inches
Explore the typical applications for both Mil/Thou (imperial/US) and Inch (imperial/US) to understand their common contexts.
Common Uses for mils
1. Precision Manufacturing and Machining
The mil is the fundamental tolerance unit in American manufacturing:
Engineering drawings and blueprints:
- Nominal dimensions in decimal inches: 1.250″, 0.375″
- Tolerances in thousandths: ±0.005″ (±5 mils), ±0.002″ (±2 mils)
- Geometric dimensioning and tolerancing (GD&T): Position tolerance ⌖ 0.010″ (10 mils)
Quality control and inspection:
- Calipers and micrometers graduated in 0.001″ (1 mil) divisions
- Dial indicators show 0.001″ or 0.0001″ (0.1 mil) graduations
- Coordinate measuring machines (CMM) measure to ±0.1 mil or better
- Pass/fail gauges: "Go" and "No-Go" plugs/rings differ by a few mils
Real-world tolerances by industry:
- General fabrication: ±5-10 mils (±0.005-0.010″)
- Automotive production: ±2-5 mils typical
- Aerospace critical parts: ±0.5-2 mils
- Medical implants (hip, knee): ±0.2-1 mil
- Semiconductor equipment: ±0.1 mil (±100 microinches)
Example: A shaft specified as Ø 1.000″ ± 0.002″ must measure between 0.998″ and 1.002″ (within ±2 mils). A shaft measuring 1.003″ (3 mils over) would be rejected.
2. Coating Thickness Measurement
Paint, plating, and protective coating thickness is universally measured in mils in American industry:
Paint inspection (wet film thickness gauges):
- Notch gauges (comb-style): Teeth graduated in mils (2, 4, 6, 8, 10 mils)
- Painter inserts gauge into wet paint; highest clean tooth indicates thickness
- Ensures proper coverage to meet specification (e.g., "apply to 6 mils wet film")
Dry film thickness (DFT) measurement:
- Magnetic gauges (ferrous substrates): Reed sensor or Hall effect, calibrated in mils
- Eddy current gauges (non-ferrous): For aluminum, brass, copper substrates
- Ultrasonic gauges: For non-metallic coatings on any substrate
Industry specifications:
- SSPC-PA 2 (paint inspection): Requires DFT measurement in mils
- U.S. Navy painting specs: Minimum DFT requirements (e.g., 5-7 mils for topcoat)
- Automotive OEM specs: Total paint system 4-6 mils
- Industrial maintenance coatings: Often 8-15 mils for severe environments
Example: A steel bridge specification might require: "Apply epoxy primer to 5-8 mils DFT, followed by polyurethane topcoat to 3-5 mils DFT." Inspectors measure at multiple points; any reading below minimum triggers rework.
Galvanizing and plating:
- Hot-dip galvanizing: ASTM A123 requires minimum 2.0 mils (for <1/4″ thick steel)
- Chrome plating: 0.5-1 mil decorative, 8-10 mils hard chrome (wear resistance)
- Anodizing (aluminum): Type II = 0.2-0.7 mils, Type III (hard anodize) = 2-4 mils
3. Plastic Film and Flexible Packaging
Plastic film thickness is specified in mils in the U.S. packaging industry:
Food packaging films:
- Shrink wrap: 2-4 mils (60-100 μm)
- Stretch wrap (pallet wrap): 12-20 gauge = 0.5-0.8 mil (gauge ≠ mils, confusingly)
- Vacuum seal bags (FoodSaver): 3-4 mils
- Frozen food bags: 2-3 mils
- Thicker film = better puncture resistance, higher material cost
Construction and industrial films:
- Vapor barriers (under-slab): 6-10 mils required by building codes
- Construction tarps: 5-12 mils depending on duty
- Agricultural greenhouse film: 4-6 mils (UV-stabilized)
- Geomembrane liners (landfills, ponds): 20-100 mils
Adhesive tapes:
- Scotch tape (Transparent): 1-1.5 mils
- Masking tape: 5-7 mils total thickness
- Duct tape: 10-12 mils
- Double-sided foam tape: 30-60 mils
- Specification includes backing + adhesive thickness
Industry standards:
- ASTM D6988: Standard specification for polyethylene film (thickness in mils)
- ASTM D374: Method for measuring tape thickness (to 0.1 mil)
Example: A customer ordering "6-mil poly sheeting" for a concrete vapor barrier receives polyethylene film exactly 0.006″ (6 mils = 0.15 mm) thick, ensuring compliance with IRC building code.
4. Electronics and Printed Circuit Boards
PCB design and manufacturing is dominated by mil-based dimensions in the United States:
PCB design software (Altium, Eagle, KiCAD, OrCAD):
- Default grid spacing: 50 mils, 25 mils, 10 mils, 5 mils, 1 mil
- Component libraries use 100-mil pin spacing for through-hole parts
- Trace width and clearance rules specified in mils
Design rules and capabilities:
- Standard PCB fabrication (budget services):
- Minimum trace width: 6 mils
- Minimum spacing: 6 mils
- Via drill: 8-10 mils
- Copper weight: 1 oz (1.4 mils)
- Advanced PCB fabrication:
- Minimum trace/space: 3 mil / 3 mil
- Microvias: 4-6 mil drill
- HDI (high-density interconnect): sub-mil features
Copper thickness selection:
- 1 oz copper (1.4 mils): Standard for signal layers, adequate for currents <3A
- 2 oz copper (2.8 mils): Power planes, higher current capacity (5-10A per trace)
- 3-4 oz copper (4.2-5.6 mils): Power electronics, automotive
- Current-carrying capacity increases with thickness (more copper = less resistance = less heat)
PCB stackup (multilayer boards):
- 4-layer board example:
- Top copper: 1.4 mils (1 oz)
- Prepreg: 7 mils
- Inner layer 1 (ground): 1.4 mils
- Core: 47 mils
- Inner layer 2 (power): 1.4 mils
- Prepreg: 7 mils
- Bottom copper: 1.4 mils
- Total: 67 mils (1.7 mm)
Soldermask and silkscreen:
- Soldermask (green coating): 0.8-1.2 mils thickness
- Silkscreen (white text): 0.5-1 mil
- Surface finish (ENIG gold): 1-2 microinches (0.001-0.002 mil)
5. Wire Gauge and Cable Manufacturing
American Wire Gauge (AWG) is fundamentally based on diameter in mils:
AWG diameter formula:
- Each gauge step represents approximately a 1.123× change in diameter (10 steps = 1 decade = 10× area change)
- AWG 10 = 102 mils diameter
- AWG 20 = 32 mils diameter
- AWG 30 = 10 mils diameter
Wire insulation thickness (in mils over conductor diameter):
- Thin-wall insulation: 4-8 mils
- Standard insulation: 15-30 mils
- High-voltage insulation: 30-60+ mils
- Specification: "22 AWG with 10 mil insulation" = 25 mil conductor + 20 mil insulation total = 45 mil overall diameter
Magnet wire (enameled copper for motors, transformers):
- AWG 28-40 common for small coils
- Enamel coating: 0.5-2 mils depending on temperature rating
- Grade 1 (thinnest): 0.5-0.8 mil enamel
- Grade 2 (standard): 1-1.5 mil enamel
- Grade 3 (heavy build): 2-3 mil enamel
- Thicker enamel = better insulation, lower packing density in coil
Cable jacket thickness:
- Ethernet Cat6 cable jacket: 20-30 mils
- Power cord (SJOOW): 60-80 mils
- Mining cable: 125-250 mils (extreme abrasion resistance)
6. Sheet Metal and Gauge Systems
Sheet metal thickness is specified in gauge numbers, but actual thickness is in decimal inches (mils):
Manufacturer's Standard Gauge (steel):
- 10-gauge = 135 mils (0.1345″)
- 14-gauge = 75 mils (0.0747″)
- 20-gauge = 36 mils (0.0359″)
- 24-gauge = 24 mils (0.0239″)
Confusion and standardization issues:
- Gauge numbers are not universal: steel gauge ≠ aluminum gauge ≠ galvanized gauge
- Modern practice: Always specify in decimal inches (mils) to avoid ambiguity
- Example: "0.060″ aluminum" (60 mils) instead of "14-gauge aluminum"
HVAC ductwork:
- Residential ducts: 24-26 gauge (18-30 mils)
- Commercial ducts: 20-22 gauge (33-42 mils)
- Galvanized coating adds 2-5 mils to thickness
Automotive body panels:
- Hood outer skin: 28-30 mils (0.7-0.8 mm)
- Door outer skin: 26-28 mils
- Roof panel: 28-32 mils
- Frame rails: 90-120 mils (2.3-3.0 mm)
7. Quality Control and Standards Compliance
Mil-based specifications appear in thousands of ASTM, ANSI, SAE, and military standards:
ASTM coating standards:
- ASTM D3359: Adhesion of coatings (measured after cutting through coating, thickness in mils)
- ASTM D1186: Paint film thickness (magnetic gauges calibrated in mils)
- ASTM D6132: Nondestructive measurement of dry film thickness (mils)
Military specifications (MIL-SPEC):
- MIL-DTL-53030: Primer coating, epoxy, 2-3 mils DFT
- MIL-PRF-85285: Coating, polyurethane, aircraft, 1.5-2.5 mils
- Compliance requires thickness measurement at specified intervals
Building codes and construction:
- International Residential Code (IRC): Vapor retarders minimum 6 mils
- Roofing underlayment: Minimum thickness specifications in mils
- Window film (safety/security): 4-14 mils for various protection levels
Automotive and aerospace:
- SAE J1960: Brake hose specifications (wall thickness in inches/mils)
- AS9100 (aerospace quality): Dimensional inspections recorded in mils
- Engine bearing clearances: Specified in mils (e.g., 1.5-2.5 mils for main bearings)
When to Use inches
Home Construction and Renovation
Residential construction in the United States operates almost exclusively in inches and feet. Standard framing uses 16-inch or 24-inch on-center stud spacing, creating modular dimensions that align with 48-inch-wide drywall and plywood sheets. Contractors calculate materials in board feet and square footage, but individual measurements are precise to 1/16 inch.
Kitchen cabinets come in 3-inch width increments (12″, 15″, 18″, 21″, 24″, 27″, 30″, 33″, 36″), with standard depth of 24 inches for base cabinets and 12 inches for wall cabinets. Countertop height standardizes at 36 inches, while bar counters sit at 42 inches. These dimensions have remained unchanged for decades, creating an entire ecosystem of compatible fixtures, appliances, and hardware.
Tile installation relies on precise inch measurements. Floor tiles commonly measure 12″ × 12″, 12″ × 24″, or 24″ × 24″. Wall tiles might be 3″ × 6″ subway tiles or 4″ × 4″ ceramic squares. Grout line spacing typically runs 1/16″ to 1/4″ depending on tile type. Tile setters work to extremely tight tolerances, as even 1/16-inch variation across a room becomes visibly noticeable.
Manufacturing and Machining
American manufacturing maintains imperial measurements for historical and practical reasons. Machine shops operate in decimal inches (0.001″ = 1 "thou" or 1 "mil"), with precision machining achieving tolerances of ±0.0001″ (one ten-thousandth of an inch, called a "tenth").
Thread specifications use threads per inch (TPI): 1/4″-20 means a 1/4-inch diameter bolt with 20 threads per inch. Common thread pitches include coarse (UNC) and fine (UNF) standards, with sizes ranging from #0-80 (tiny electronic screws) to several inches in diameter for industrial equipment.
Sheet metal thickness traditionally uses gauge numbers (inversely related to thickness in inches). 20-gauge steel is approximately 0.036 inches thick, while 10-gauge is 0.135 inches. However, modern manufacturing increasingly specifies thickness in decimal inches (0.063″ aluminum sheet) for clarity.
CNC (Computer Numerical Control) machines can work in either inches or millimeters, but American shops predominantly program in inches. A machinist might bore a hole to 0.5005″ diameter to accept a 1/2-inch precision shaft with 0.0005″ clearance.
Fasteners and Hardware
The American fastener industry operates entirely in imperial measurements. Screw and bolt diameters are specified in fractions (1/4″, 5/16″, 3/8″, 1/2″) or gauge numbers (#4, #6, #8, #10). Thread pitch is given in threads per inch.
Common bolt sizes and their applications:
- 1/4″-20: Electronics, light fixtures, small brackets
- 5/16″-18: Medium structural connections, automotive
- 3/8″-16: Heavy brackets, machinery, automotive chassis
- 1/2″-13: Structural steel, heavy machinery, trailer hitches
- 5/8″-11: Building construction, large structural connections
- 3/4″-10: Industrial equipment, heavy structural steel
Hex keys (Allen wrenches) come in fractional inch sizes: 1/16″, 5/64″, 3/32″, 1/8″, 5/32″, 3/16″, 7/32″, 1/4″, 5/16″, and 3/8″. Metric hex keys are incompatible—a 5mm key is 0.197″, close to but not quite matching 3/16″ (0.1875″) or 1/4″ (0.25″).
Display Technology and Photography
Television and monitor sizes are universally described by screen diagonal in inches, even in metric countries. This convention originated with cathode ray tubes, where the diagonal measurement corresponded to the visible screen area inside the bezel.
Common display sizes and their uses:
- 24″ monitors: Standard office workstation
- 27″ monitors: Popular desktop size, ideal for 1440p resolution
- 32″ monitors: Large desktop or small TV
- 43″ TVs: Small bedroom TV
- 55″ TVs: Most popular living room size
- 65″ TVs: Premium living room standard
- 75″ TVs: Home theater
- 85″+ TVs: Luxury home cinema
Photography inherited imperial measurements from early camera equipment. Sensor sizes reference inches in confusing ways—a "1-inch sensor" is actually much smaller (13.2 × 8.8 mm), referencing the outer diameter of an obsolete video camera tube rather than the actual sensor dimensions.
Large format photography uses inch measurements directly: 4×5″ and 8×10″ sheet film, or medium format 6×4.5cm, 6×6cm, 6×7cm (which are actually metric despite being called 120 film).
Plumbing and Pipe Systems
Plumbing pipe sizes in the US use nominal measurements that don't match actual dimensions. A "1/2-inch pipe" has an inside diameter of approximately 0.622″ and outside diameter of 0.840″. This naming convention dates back to when pipe walls were much thicker.
Common pipe sizes and uses:
- 1/2″ nominal: Standard water supply lines to fixtures
- 3/4″ nominal: Main water supply within house
- 1″ nominal: Supply from water meter to house
- 1½″ nominal: Sink drain lines
- 2″ nominal: Toilet drain, main stack
- 3″ nominal: Main drain, sewer connection
- 4″ nominal: Main building drain and sewer
Copper pipe uses different sizing: Type M, L, and K copper all have the same outside diameter for a given size, but different wall thicknesses. PEX (cross-linked polyethylene) tubing uses actual measurements—1/2″ PEX has a 0.500″ outside diameter.
Weather Reporting and Climatology
United States weather forecasting measures precipitation in inches. The National Weather Service issues warnings based on inch thresholds:
- Flash Flood Watch: Expected 1-2 inches in one hour or 3-4 inches in several hours
- Heavy Snow Warning: 6+ inches in 12 hours or 8+ inches in 24 hours
- Blizzard Warning: 3+ hours of heavy snow with sustained winds 35+ mph
Rainfall intensity rates:
- Light rain: <0.10 inches per hour
- Moderate rain: 0.10 to 0.30 inches per hour
- Heavy rain: >0.30 inches per hour
Annual precipitation varies dramatically across the US:
- Las Vegas, NV: 4.2 inches per year (desert)
- Phoenix, AZ: 8.3 inches per year
- Los Angeles, CA: 14.9 inches per year
- New York, NY: 46.2 inches per year
- Seattle, WA: 37.5 inches per year
- Miami, FL: 61.9 inches per year
- Mobile, AL: 67.0 inches per year (wettest major US city)
- Mt. Waialeale, HI: 450+ inches per year (one of Earth's wettest places)
Automotive and Cycling
American automotive specifications traditionally use inches:
- Wheel Diameter: 15″, 16″, 17″, 18″, 19″, 20″, 22″ (passenger vehicles)
- Tire Width: Given in millimeters, but wheel size in inches (e.g., 225/65R17)
- Ground Clearance: Often stated in inches (e.g., 8.6″ clearance)
- Cargo Space: Cubic feet, with dimensions in inches
- Engine Displacement: Historically cubic inches (350 cu in = 5.7L), now usually liters
Bicycle sizing uses a mix of systems. Mountain bike wheels measure 26″, 27.5″ (650B), or 29″ in diameter. Road bikes use the 700c standard (approximately 27″ diameter, derived from French sizing). Frame sizes might be given in inches (17″ mountain bike) or centimeters (56cm road bike) depending on manufacturer and tradition.
HVAC and Duct Work
Heating, ventilation, and air conditioning (HVAC) systems in the US specify duct sizes in inches. Rectangular ductwork might be 6″ × 10″, 8″ × 12″, or 10″ × 16″. Round ducts come in 4″, 6″, 8″, 10″, and 12″ diameters.
Air register and vent sizes are standardized in inches:
- Floor registers: 4″ × 10″, 4″ × 12″, 4″ × 14″
- Wall registers: 6″ × 10″, 6″ × 12″, 8″ × 10″
- Return air grilles: 14″ × 24″, 16″ × 20″, 20″ × 20″
Furnace filters use inch sizing: 16″ × 20″ × 1″, 16″ × 25″ × 1″, 20″ × 25″ × 4″. The first two dimensions are the face size, and the third is the thickness. Standard filters are 1″ thick, while pleated media filters might be 4″ or 5″ thick for better filtration and airflow.
Additional Unit Information
About Mil/Thou (mil)
Is a mil the same as a millimeter?
No—they are very different units, despite similar names.
- 1 mil (imperial) = 0.001 inches = 0.0254 mm = 25.4 micrometers
- 1 millimeter (metric) = 0.001 meters = 39.37 mils
Key difference: 1 millimeter is approximately 40 times larger than 1 mil. Confusing these units results in massive errors (40× too thick or thin).
Origin of confusion: "Mil" sounds like an abbreviation for "millimeter," but it actually comes from the Latin "mille" (thousand), meaning one thousandth of an inch. In some non-English languages, "mil" or "mil." is used as slang for millimeter, compounding confusion in international contexts.
Prevention: Always write units explicitly—"6 mils (0.15 mm)" or "0.2 mm (7.9 mils)"—in international specifications.
What does 'thou' mean, and is it the same as a mil?
Yes—"thou" and "mil" are exactly the same measurement: one thousandth of an inch (0.001″).
Regional differences:
- "Mil" is standard in American technical documentation, industry standards (ASTM, ANSI, SAE), and scientific publications.
- "Thou" is common in British English shop-floor terminology, machining, and colloquial engineering speech.
Etymology:
- "Mil" comes from Latin "mille" (thousand)
- "Thou" is an abbreviation of "thousandth" (of an inch)
Usage examples:
- American engineer: "Tolerance is plus or minus five mils."
- British machinist: "Take another two thou off the diameter."
- Both mean exactly: 0.005″ and 0.002″ respectively.
Documentation practice: Technical drawings and specifications predominantly use "mil" or the decimal notation (0.001″), while "thou" appears more in verbal communication and informal notes.
How many mils are in an inch?
Exactly 1,000 mils = 1 inch by definition.
The mil is defined as one thousandth of an inch:
- 1 mil = 0.001″
- 1 inch = 1,000 mils
Common fractions converted to mils:
- 1/2″ = 500 mils
- 1/4″ = 250 mils
- 1/8″ = 125 mils
- 1/16″ = 62.5 mils
- 1/32″ = 31.25 mils
- 1/64″ = 15.625 mils
This decimal subdivision makes arithmetic much easier than traditional fractional inches (no need to find common denominators).
Why do we still use mils instead of millimeters?
Several practical and historical reasons explain the mil's persistence in American industry despite global metrication:
1. Legacy infrastructure (strongest reason):
- Billions of dollars invested in tooling, fixtures, gauges, and manufacturing equipment calibrated in inches/mils
- Converting existing designs and technical documentation is prohibitively expensive and risky
- Critical industries (aerospace, defense, medical) have decades of proven designs that cannot be easily converted
2. Compatibility and interchangeability:
- Replacing a part requires exact dimensional compatibility
- Mixed mil/metric systems in a single product line risk catastrophic errors (e.g., 1999 Mars Climate Orbiter loss due to metric/imperial confusion)
- Entire supply chains (thousands of vendors) must convert simultaneously for compatibility
3. Established standards:
- American Wire Gauge (AWG) is based on mils
- ASTM, ANSI, SAE, and military specifications (MIL-SPEC) use mils
- Rewriting thousands of standards documents is a monumental undertaking
4. Practical advantages in some contexts:
- PCB design: 100-mil (0.1″) pin spacing is convenient, memorable, and grid-friendly
- Engineering calculations: Tolerances like "±5 mils" are intuitive to experienced engineers
- Decimal-inch system avoids fractional arithmetic while maintaining imperial base
5. Economic inertia:
- No compelling economic driver for conversion in purely domestic manufacturing
- Cost of conversion (training, documentation, tooling) outweighs benefits in mature industries
6. Cultural and educational factors:
- American engineers trained in decimal-inch system for generations
- Familiarity breeds efficiency—experienced machinists "think in mils"
Counterpoint: Industries with strong international ties (automotive, consumer electronics) increasingly use dual dimensioning (both mils and mm) or have shifted to metric. New designs often start in metric, but maintenance of existing imperial products ensures mils remain relevant for decades.
How do I convert mils to micrometers (microns)?
Multiply mils by 25.4 to get micrometers (μm):
Formula: μm = mils × 25.4
Examples:
- 1 mil × 25.4 = 25.4 μm
- 5 mils × 25.4 = 127 μm
- 10 mils × 25.4 = 254 μm
- 100 mils × 25.4 = 2,540 μm (= 2.54 mm)
Reverse conversion (micrometers to mils): Divide by 25.4
Formula: mils = μm ÷ 25.4
Examples:
- 50 μm ÷ 25.4 = 1.97 mils (≈ 2 mils)
- 100 μm ÷ 25.4 = 3.94 mils (≈ 4 mils)
- 250 μm ÷ 25.4 = 9.84 mils (≈ 10 mils)
Why 25.4? Because 1 inch = 25.4 mm exactly (by the 1959 international agreement), and 1 mil = 0.001 inch, so:
- 1 mil = 0.001 inch × 25.4 mm/inch = 0.0254 mm = 25.4 μm
Practical use: Coating thickness specifications often appear in both units:
- "Apply to 5 mils (127 μm) dry film thickness"
- Ensures international suppliers understand the requirement
What is 1 mil in metric units?
1 mil = 25.4 micrometers (μm) = 0.0254 millimeters (mm) exactly.
Complete metric equivalents:
- 1 mil = 25.4 μm (most common metric expression for precision work)
- 1 mil = 0.0254 mm (less common, but useful for larger scales)
- 1 mil = 0.0000254 meters
- 1 mil = 25,400 nanometers (semiconductor/optics context)
Reverse:
- 1 micrometer (μm) = 0.03937 mil (≈ 1/25 mil)
- 1 millimeter (mm) = 39.37 mils (≈ 40 mils for quick estimation)
Why exactly 25.4? The 1959 international yard and pound agreement defined:
- 1 inch = 25.4 mm exactly
- Therefore: 1 mil = 0.001 inch = 25.4 μm exactly
This is not an approximation—it's the legal definition linking imperial and metric systems.
How thick is 4 mils?
4 mils = 0.004 inches = 0.1 mm (100 micrometers) — about the thickness of standard printer paper.
Everyday comparisons for 4 mils:
- Two sheets of standard copy paper stacked (each ~4 mils)
- Human hair is roughly 2× thicker (70-100 mils vs. 4 mils)
- Credit card is roughly 7.5× thicker (30 mils vs. 4 mils)
- Fingernail is roughly 5-7× thicker (20-30 mils)
Common uses of 4-mil thickness:
- Printer/copy paper (20 lb bond): 3.5-4.5 mils
- Automotive paint (single coat): 1.5-2 mils base + 1.5-2 mils clear = 4-5 mils total
- Polyethylene sheeting (light-duty drop cloths): 3-4 mils
- House paint (exterior, dry film): 1.5-2 coats × 2 mils each = 4-5 mils
Feeling 4 mils: Too thin to feel accurately with fingers—requires calipers or micrometer to measure precisely.
What is considered a tight tolerance in mils?
"Tight" tolerances depend on the manufacturing process and application, but general industry standards are:
General fabrication and commercial machining:
- Loose tolerance: ±10-20 mils (±0.010-0.020″)
- Standard tolerance: ±5 mils (±0.005″)
- Tight tolerance: ±1-2 mils (±0.001-0.002″)
Precision machining:
- Standard: ±1 mil (±0.001″)
- Tight: ±0.5 mil (±0.0005″)
- Very tight: ±0.1-0.2 mil (±100-200 microinches)
Ultra-precision (grinding, diamond turning):
- Tight: ±0.05 mil (±50 microinches = ±1.3 μm)
- Extremely tight: ±0.01 mil (±10 microinches = ±0.25 μm)
Application examples:
- Engine piston fit: 1-3 mils clearance (0.001-0.003″) — critical for sealing and oil retention
- Bearing journals: ±0.5 mil tolerance — affects bearing life and performance
- Hydraulic valve spool: 0.5-1 mil clearance — controls internal leakage
- Gauge blocks (Grade 0): ±0.05 mil (±50 microinches) — calibration standard
- Optical lens mounts: ±0.1 mil — affects focus and alignment
Cost impact: Tighter tolerances require:
- More precise equipment (CNC machining centers, grinders)
- Slower machining speeds and feeds
- More frequent inspection
- Skilled machinists
- Climate-controlled environment (for extreme precision)
Rule of thumb: Each 10× reduction in tolerance (e.g., ±10 mils → ±1 mil → ±0.1 mil) roughly doubles or triples machining cost.
How do you measure thickness in mils?
Several tools measure thickness in mils, depending on the material and access:
1. Micrometer (most common for solid parts):
- Handheld precision tool with anvil and spindle
- Resolution: 0.001″ (1 mil) for standard micrometers; 0.0001″ (0.1 mil) for digital or vernier micrometers
- How to use: Place object between anvil and spindle, turn thimble until it contacts with light resistance, read measurement
- Accuracy: ±0.0001″ (±0.1 mil) or better when calibrated
- Best for: Solid materials (sheet metal, plastic, gaskets, wire)
2. Digital calipers:
- Resolution: Typically 0.001″ (1 mil) or 0.01 mm
- Easier to read than dial calipers (digital display)
- Less precision than micrometers (±1-2 mils accuracy)
- Best for: Quick measurements, larger parts, non-critical dimensions
3. Coating thickness gauges (for paint/plating):
- Magnetic gauges (ferrous substrates): Reed switch or Hall effect sensor detects distance through non-magnetic coating
- Eddy current gauges (non-ferrous substrates): Measures impedance change due to coating thickness
- Ultrasonic gauges: Sound wave reflection for non-metallic coatings or any substrate
- Resolution: Typically 0.1 mil (2.5 μm) to 1 mil depending on model
- Best for: Paint, powder coating, galvanizing, plating, anodizing on metal substrates
4. Wet film thickness gauges (paint application):
- Notch/comb gauges: Comb with graduated teeth (2, 4, 6, 8, 10 mils)
- How to use: Insert comb perpendicular into wet paint; highest clean tooth (no paint) indicates thickness
- Resolution: Depends on tooth spacing (typically 2 mil increments)
- Best for: Field inspection during painting to ensure proper application
5. Dial indicators (for comparing thickness):
- Measures variation rather than absolute thickness
- Place part on reference surface, indicator plunger contacts top
- Resolution: 0.001″ (1 mil) or 0.0001″ (0.1 mil) for precision models
- Best for: Checking flatness, parallelism, thickness variation across a surface
6. Optical/laser micrometers (non-contact):
- Laser beam measures shadow of object passing through
- Resolution: Sub-mil (0.01-0.1 mil) depending on model
- Best for: Soft materials (rubber, foam) or high-speed production inspection (wire, cable)
Calibration: All precision measuring tools require regular calibration against gauge blocks or calibration standards to maintain accuracy.
Why is PCB design done in mils?
PCB (printed circuit board) design uses mils primarily due to historical legacy and practical convenience in American electronics manufacturing:
1. Component standards based on 100-mil spacing:
- Through-hole components (resistors, ICs, connectors) were standardized with 0.1″ (100 mil) pin spacing in the 1950s-1970s
- Dual in-line packages (DIP): Pins spaced at 100 mil intervals
- Perfboard and breadboards: 100 mil grid for prototyping
- This 100-mil standard became embedded in component libraries and CAD software
2. PCB design grid convenience:
- Grid snapping: CAD software uses grids (50 mil, 25 mil, 10 mil, 5 mil, 1 mil)
- 100 mil grid allows easy component placement aligned with standard pin spacing
- Fractional grids: 50 mil (0.05″), 25 mil (0.025″) for routing between pins
- Metric equivalents (2.54 mm, 1.27 mm, 0.635 mm) are awkward, non-round numbers
3. Trace width and spacing in convenient numbers:
- Typical design rules: 6 mil trace / 6 mil space (easier to remember than "0.15 mm / 0.15 mm")
- High-current traces: 15 mil, 20 mil, 30 mil widths (round numbers)
- Advanced designs: 3 mil / 3 mil minimum capability
4. Standard PCB thickness:
- 62 mils (1.57 mm) is the industry-standard board thickness—originated in imperial measurements
- Thinner boards: 31 mils (0.8 mm), 47 mils (1.2 mm)
- Thicker boards: 93 mils (2.4 mm), 125 mils (3.2 mm)
5. Copper weight in oz/ft² naturally maps to mils:
- 1 oz copper = 1.4 mils thick (34.8 μm)
- 2 oz copper = 2.8 mils thick
- Easy calculation for impedance and current capacity
6. Legacy and tool compatibility:
- Enormous library of existing designs, footprints, and components in mil units
- PCB CAD software (Altium, Eagle, OrCAD, KiCAD) default to mils in U.S. installations
- Converting to metric risks errors and incompatibility with legacy designs
Modern trend: Some international PCB design now uses metric (especially in Europe and Asia), but American designs and military/aerospace specs remain overwhelmingly mil-based. Many CAD tools support dual dimensioning to bridge both systems.
Are mils still relevant today, or is it an obsolete unit?
Mils are absolutely still relevant and widely used in American manufacturing, despite global metrication trends. The unit is not obsolete—it remains the standard in several major industries:
Industries actively using mils today (2020s):
1. Printed circuit board (PCB) and electronics manufacturing:
- Trace widths, spacing, and via sizes specified in mils
- Component libraries and footprints use 100-mil pin spacing
- Standard fabrication capabilities: "6 mil trace / 6 mil space"
2. Aerospace and defense:
- Military specifications (MIL-SPEC) use mils for tolerances and coating thickness
- Legacy aircraft designs (Boeing, Lockheed Martin) remain in decimal-inch/mil system
- Interchangeable parts for decades-old platforms require dimensional consistency
3. Precision machining and manufacturing:
- Tolerances routinely specified in mils (±1 mil, ±5 mil)
- Micrometer readings in decimal inches (thousandths)
- CNC programming often in inches/mils in American shops
4. Coating and painting industries:
- ASTM and SSPC standards specify dry film thickness (DFT) in mils
- Paint thickness gauges calibrated in mils
- Industrial specifications: "8-10 mils total coating system"
5. Plastic film and flexible packaging:
- Film thickness: "6-mil poly sheeting," "4-mil polyester film"
- ASTM standards for plastic film thickness use mils
6. Wire and cable manufacturing:
- American Wire Gauge (AWG) based on diameter in mils
- Insulation thickness specified in mils over conductor
7. Sheet metal fabrication:
- Actual thickness often specified in decimal inches (mils) to avoid gauge confusion
- "0.063″ aluminum" (63 mils) instead of ambiguous "14-gauge"
Why mils persist:
- Billions in tooling and infrastructure calibrated in imperial units
- Legacy designs: Decades of proven engineering in mils cannot be easily converted
- Risk avoidance: Metric/imperial conversion errors are costly and dangerous (Mars Climate Orbiter)
- Supply chain compatibility: Entire ecosystems of suppliers and manufacturers use consistent units
- No economic driver: Purely domestic manufacturing has little incentive to convert
Metric adoption: Global companies (automotive, consumer electronics) increasingly use dual dimensioning (both mils and mm) or shift new designs to metric, but maintenance and support of existing products ensures mils remain relevant for decades.
Conclusion: Mils are actively used, not obsolete, and will remain standard in American manufacturing for the foreseeable future—especially in aerospace, defense, electronics, and precision machining.
What's the difference between a mil and a milliradian?
Completely different units from different measurement domains—they only share a similar name:
Mil (length):
- Unit of length = 0.001 inches (one thousandth of an inch)
- Used in manufacturing, coating thickness, electronics, tolerances
- Example: "The coating is 5 mils thick."
Milliradian (angular measurement):
- Unit of angle = 0.001 radians ≈ 0.0573 degrees
- Used in artillery, ballistics, marksmanship, optics, surveying
- Example: "The rifle scope adjustment is 0.1 milliradian per click."
No conversion between them—they measure fundamentally different things (distance vs. angle).
Confusing terminology: In military and shooting contexts, "mil" is often shorthand for milliradian (angular mil), while in manufacturing, "mil" always means 0.001 inch (linear mil). Context determines meaning.
Additional angular "mil" units (adding to confusion):
- NATO mil (milliradian): 1/1000 radian ≈ 0.0573°
- Swedish/metric mil: 1/6000 of a circle ≈ 0.06° (slightly larger than milliradian)
- Artillery mil (historical): 1/6400 of a circle ≈ 0.05625°
Summary: Unless you're discussing ballistics or optics, "mil" refers to 0.001 inch in American industry and manufacturing.
About Inch (in)
How many inches are in a foot?
There are exactly 12 inches in one foot. This relationship is fixed by definition in the US customary and imperial systems. The division of a foot into 12 parts dates back to ancient Roman measurements and remained standard because 12 is easily divisible by 2, 3, 4, and 6—making fractional measurements convenient in practical applications.
To convert feet to inches, multiply by 12. To convert inches to feet, divide by 12.
- 5 feet = 5 × 12 = 60 inches
- 48 inches = 48 ÷ 12 = 4 feet
- 3 feet 7 inches = (3 × 12) + 7 = 43 inches total
How many centimeters are in an inch?
One inch equals exactly 2.54 centimeters. This relationship was established by the 1959 international yard and pound agreement, which defined the yard as exactly 0.9144 meters. Since one inch equals 1/36 of a yard, it works out to precisely 2.54 cm.
This is one of the few perfectly defined relationships between imperial and metric systems. There's no rounding or approximation—it's exactly 2.54000... cm per inch by international agreement.
To convert inches to centimeters, multiply by 2.54. To convert centimeters to inches, divide by 2.54.
- 10 inches = 10 × 2.54 = 25.4 cm
- 50 cm = 50 ÷ 2.54 = 19.685 inches
Why does the US still use inches instead of the metric system?
The United States remains one of only three countries (along with Myanmar and Liberia) not officially using the metric system, largely due to historical momentum, infrastructure costs, and cultural identity.
Infrastructure Investment: The US has trillions of dollars invested in imperial-based infrastructure—road signs showing miles, construction materials in feet and inches, manufacturing equipment calibrated in thousandths of an inch, pipelines in inch diameters, and billions of blueprints in feet-inches notation. Converting all of this would cost an estimated $370 billion to $1 trillion.
Industry Standardization: American manufacturing, construction, and engineering have perfected systems around imperial measurements over centuries. Millions of workers are trained in inches and feet. Changing would require retraining entire industries and replacing countless tools, gauges, and documentation.
Cultural Resistance: Americans intuitively understand inches, feet, and miles from childhood. Polls consistently show that most Americans oppose mandatory metric conversion, viewing it as unnecessary government overreach. Unlike temperature (where Fahrenheit provides finer granularity for weather), length measurements in inches don't provide any practical advantage—but changing feels like abandoning tradition.
Failed Conversion Attempts: Congress passed the Metric Conversion Act in 1975, making metric the "preferred system" but keeping adoption voluntary. Without enforcement, industries continued using imperial. A 1982 push to convert road signs to kilometers was abandoned after fierce public backlash.
Partial Adoption: The US actually uses metric extensively in science, medicine, military, and some industries. All US customary units are now legally defined in terms of metric units. Americans live in a hybrid system—drinking 2-liter sodas while driving 65 miles per hour.
What's the difference between decimal inches and fractional inches?
Fractional inches express measurements as common fractions: 1/2″, 3/4″, 5/8″, 7/16″, 15/32″. This system dominates carpentry, construction, and mechanical work. Rulers and tape measures show fraction markings—typically down to 1/16″ for standard use and 1/32″ for precision carpentry.
Decimal inches express measurements as decimal values: 0.5″, 0.75″, 0.625″, 0.4375″, 0.46875″. Engineering drawings, machining, and manufacturing prefer decimals because they're easier to calculate with, especially for tolerances and fits.
Both systems describe the same measurements:
- 1/2″ = 0.500″
- 3/4″ = 0.750″
- 5/8″ = 0.625″
- 1/8″ = 0.125″
Machine shops often work in "thousandths" (0.001″, called a "thou" or "mil") for precision. A machinist might drill a 0.257″ diameter hole—trying to express this as a fraction (257/1000″) would be impractical.
Carpenters and builders work in fractions because tape measures show fractions, and because halving measurements repeatedly (1/2, 1/4, 1/8, 1/16, 1/32) is natural in layout work.
How accurate is an inch measurement?
The definition of an inch is exact: 2.54 centimeters precisely, or 25.4 millimeters. There's no uncertainty in the standard itself.
Practical accuracy depends on the measuring tool:
- Ruler or tape measure: Accurate to roughly ±1/16″ (±1.6 mm) for careful work
- Steel ruler with machinist's markings: ±1/32″ (±0.8 mm) when read carefully
- Dial calipers: ±0.001″ (±0.025 mm) typical accuracy
- Digital calipers: ±0.0005″ (±0.013 mm) for quality instruments
- Micrometers: ±0.0001″ (±0.0025 mm) for precision tools
- Coordinate measuring machines (CMM): ±0.00005″ (±0.0013 mm) or better
Different trades require different precision:
- House framing: ±1/8″ is usually acceptable
- Finish carpentry: ±1/16″ or better for visible joints
- Cabinetmaking: ±1/32″ for tight-fitting doors and drawers
- Machining: ±0.001″ (one thousandth) for standard fits
- Precision machining: ±0.0001″ (one ten-thousandth, called a "tenth")
- Gauge blocks (calibration standards): Accurate to millionths of an inch
Can I use a metric wrench on an inch bolt?
Generally no—metric and imperial fasteners are incompatible. While some sizes appear close, using the wrong wrench damages bolt heads and nuts.
Why they're incompatible: Metric sockets and wrenches are sized in millimeters (8mm, 10mm, 13mm, 17mm), while imperial fasteners use fractional inches (5/16″, 3/8″, 1/2″, 5/8″). These don't align:
- 13mm = 0.512″ (close to 1/2″ = 0.500″, but not exact)
- 10mm = 0.394″ (between 3/8″ = 0.375″ and 7/16″ = 0.438″)
The result: A 13mm wrench on a 1/2″ bolt will be 0.012″ too large—enough to round off the hex corners with sufficient force. A 10mm wrench on a 3/8″ bolt won't fit at all.
Exception: In an emergency, you might carefully use a slightly large adjustable wrench or locking pliers, but this risks damaging the fastener. Always use the correct system—if you work on American-made equipment, you need inch tools. For European or Japanese equipment, you need metric tools.
Many professional mechanics maintain complete sets of both imperial and metric sockets, wrenches, and hex keys—a significant investment but essential for working on diverse equipment.
What does the ″ symbol mean?
The double prime symbol ″ represents inches in technical drawings, blueprints, and mathematical contexts. A single prime ′ represents feet.
Standard notation:
- 5′ = five feet
- 5″ = five inches
- 5′-3″ = five feet, three inches
- 5′-3½″ = five feet, three and a half inches
Origin: These symbols come from astronomical and geometric notation, where they represented divisions of degrees (°). A degree divided by 60 gives minutes (′), and a minute divided by 60 gives seconds (″). This notation was borrowed for feet and inches because of the similar subdividing relationship.
Common substitution: Because typewriters and keyboards lack easy access to proper prime symbols, people often substitute:
- Apostrophe (') for feet: 5' tall
- Quotation mark (") for inches: 5" wide
- Both together: 5'-3" tall
In professional CAD drawings and blueprints, proper prime symbols (′ and ″) are standard. In casual writing, apostrophes and quotes are acceptable and universally understood.
How is screen size measured in inches?
Display screen sizes (TVs, monitors, tablets, smartphones) are always measured diagonally from one corner to the opposite corner, measuring only the visible screen area (not the bezel or frame).
Why diagonal? This convention originated with cathode ray tubes (CRTs), where the diagonal measurement corresponded to the size of the round tube face. When rectangular screens became standard, the diagonal measurement convention persisted for consistency.
Practical dimensions for common sizes:
TVs (16:9 aspect ratio):
- 55″ diagonal = approximately 48″ wide × 27″ tall
- 65″ diagonal = approximately 56.7″ wide × 31.9″ tall
- 75″ diagonal = approximately 65.4″ wide × 36.8″ tall
Monitors (16:9 aspect ratio):
- 24″ diagonal = approximately 20.9″ wide × 11.8″ tall
- 27″ diagonal = approximately 23.5″ wide × 13.2″ tall
Why this matters: When planning where to place a TV or monitor, you need the actual width and height, not the diagonal. Always check specifications for exact dimensions. Also add 1-2 inches in each direction to account for the bezel.
How do I convert inches to millimeters?
To convert inches to millimeters, multiply by 25.4. This gives you an exact result because the inch is legally defined as exactly 2.54 centimeters (25.4 millimeters).
Formula: millimeters = inches × 25.4
Examples:
- 1 inch = 1 × 25.4 = 25.4 mm
- 2 inches = 2 × 25.4 = 50.8 mm
- 0.5 inches = 0.5 × 25.4 = 12.7 mm
- 10 inches = 10 × 25.4 = 254 mm
- 3.25 inches = 3.25 × 25.4 = 82.55 mm
Converting fractional inches: First convert the fraction to a decimal, then multiply by 25.4:
- 1/2″ = 0.5″ = 0.5 × 25.4 = 12.7 mm
- 3/4″ = 0.75″ = 0.75 × 25.4 = 19.05 mm
- 5/8″ = 0.625″ = 0.625 × 25.4 = 15.875 mm
- 1/8″ = 0.125″ = 0.125 × 25.4 = 3.175 mm
Reverse conversion (mm to inches): Divide millimeters by 25.4:
- 50 mm = 50 ÷ 25.4 = 1.969 inches (approximately 2 inches)
- 100 mm = 100 ÷ 25.4 = 3.937 inches (approximately 4 inches)
For quick mental estimates, remember that 25mm ≈ 1 inch. This gives you approximately correct values for rough planning, though it slightly underestimates (25mm is actually 0.984 inches).
Why are lumber dimensions not the actual size?
Lumber in the United States is sold using nominal dimensions—traditional names that don't match the actual milled size. A "2×4" is actually 1.5″ × 3.5″, not 2″ × 4″.
Historical reason: Originally, rough-cut lumber fresh from the sawmill did measure 2″ × 4″. However, the lumber then went through drying (removing moisture) and planing (smoothing surfaces), which reduced dimensions by approximately 1/4″ on each face. Rather than rename everything, the industry kept nominal sizing for ordering convenience while standardizing actual dimensions.
Standard actual dimensions:
- 2×4 → 1.5″ × 3.5″
- 2×6 → 1.5″ × 5.5″
- 2×8 → 1.5″ × 7.25″
- 2×10 → 1.5″ × 9.25″
- 2×12 → 1.5″ × 11.25″
- 4×4 → 3.5″ × 3.5″
- 1×4 → 0.75″ × 3.5″
- 1×6 → 0.75″ × 5.5″
These dimensions are mandated by the American Softwood Lumber Standard (PS 20-20) and are consistent across all retailers.
Why this system persists: Construction is designed around nominal dimensions. Studs are spaced "16 inches on center" in walls, but everyone understands the actual stud is 1.5″ thick. Changing to actual dimension naming would require rewriting building codes, retraining millions of workers, and changing century-old industry conventions.
Important for DIY: Always design projects using actual lumber dimensions, not nominal. If you're building something that needs to be exactly 4 inches wide, a 2×4 laid flat won't work—it's only 3.5 inches.
What is the smallest measurement on a standard tape measure?
Most standard tape measures used in construction and carpentry show markings down to 1/16 inch as the smallest division. Each inch is divided into 16 equal parts, with various line lengths to indicate fractions:
- Longest lines: Every inch (1″, 2″, 3″...)
- Next longest: Half inches (1/2″, 1½″, 2½″...)
- Medium lines: Quarter inches (1/4″, 3/4″, 1¼″...)
- Shorter lines: Eighths (1/8″, 3/8″, 5/8″, 7/8″)
- Shortest lines: Sixteenths (1/16″, 3/16″, 5/16″... through 15/16″)
Precision tape measures for finish carpentry may show 1/32-inch divisions, doubling the number of marks. These are harder to read but provide twice the precision for fine woodworking.
Reading tape measures: The marks use a graduated system where longer marks indicate simpler fractions. The 1/2″ mark is the longest subdivision line, the 1/4″ and 3/4″ marks are slightly shorter, the 1/8″ marks are shorter still, and the 1/16″ marks are the shortest. This visual hierarchy makes it easier to count marks and identify positions quickly without having to count every line.
Practical accuracy: Even with 1/16″ markings, human error in marking and cutting typically limits practical accuracy to about ±1/16″ for construction work. Finish carpentry might achieve ±1/32″ with careful measurement and sharp marking.
For measurements more precise than 1/32 inch, professionals use dial calipers (readable to 0.001″) or digital calipers rather than tape measures.
Conversion Table: Mil/Thou to Inch
| Mil/Thou (mil) | Inch (in) |
|---|---|
| 0.5 | 0.001 |
| 1 | 0.001 |
| 1.5 | 0.002 |
| 2 | 0.002 |
| 5 | 0.005 |
| 10 | 0.01 |
| 25 | 0.025 |
| 50 | 0.05 |
| 100 | 0.1 |
| 250 | 0.25 |
| 500 | 0.5 |
| 1,000 | 1 |
People Also Ask
How do I convert Mil/Thou to Inch?
To convert Mil/Thou to Inch, enter the value in Mil/Thou in the calculator above. The conversion will happen automatically. Use our free online converter for instant and accurate results. You can also visit our length converter page to convert between other units in this category.
Learn more →What is the conversion factor from Mil/Thou to Inch?
The conversion factor depends on the specific relationship between Mil/Thou and Inch. You can find the exact conversion formula and factor on this page. Our calculator handles all calculations automatically. See the conversion table above for common values.
Can I convert Inch back to Mil/Thou?
Yes! You can easily convert Inch back to Mil/Thou by using the swap button (⇌) in the calculator above, or by visiting our Inch to Mil/Thou converter page. You can also explore other length conversions on our category page.
Learn more →What are common uses for Mil/Thou and Inch?
Mil/Thou and Inch are both standard units used in length measurements. They are commonly used in various applications including engineering, construction, cooking, and scientific research. Browse our length converter for more conversion options.
For more length conversion questions, visit our FAQ page or explore our conversion guides.
Helpful Conversion Guides
Learn more about unit conversion with our comprehensive guides:
📚 How to Convert Units
Step-by-step guide to unit conversion with practical examples.
🔢 Conversion Formulas
Essential formulas for length and other conversions.
⚖️ Metric vs Imperial
Understand the differences between measurement systems.
⚠️ Common Mistakes
Learn about frequent errors and how to avoid them.
All Length Conversions
Other Length Units and Conversions
Explore other length units and their conversion options:
- Meter (m) • Mil/Thou to Meter
- Kilometer (km) • Mil/Thou to Kilometer
- Hectometer (hm) • Mil/Thou to Hectometer
- Decimeter (dm) • Mil/Thou to Decimeter
- Centimeter (cm) • Mil/Thou to Centimeter
- Millimeter (mm) • Mil/Thou to Millimeter
- Foot (ft) • Mil/Thou to Foot
- Yard (yd) • Mil/Thou to Yard
- Mile (mi) • Mil/Thou to Mile
- Nautical Mile (NM) • Mil/Thou to Nautical Mile
Verified Against Authority Standards
All conversion formulas have been verified against international standards and authoritative sources to ensure maximum accuracy and reliability.
National Institute of Standards and Technology — Official US standards for length measurements
Bureau International des Poids et Mesures — International System of Units official documentation
Last verified: December 3, 2025