KRC ManufacturingCustom parts
New Knoxville, Ohio
CNC design / KRC Manufacturing

Inside Corner Radii

Why milled pockets have rounded internal corners—and how to choose a radius that supports the part’s function.

PRACTICAL DESIGN GUIDANCE · UPDATED OCTOBER 2026
DESIGN / CORNER RADIIKRC / FIELD NOTES
Inside Corner Radii — technical illustration
Technical illustration · not to scale
Cutter diameterD
Geometric tool radiusD ÷ 2
Illustration0.500 in cutter → 0.250 in radius
Design directionUse larger radii when function allows
The useful starting point

A larger inside radius usually permits a larger, more rigid cutter. Small radii become especially expensive in deep pockets.

01 /

The tool creates a radius

An end mill is round, so the internal corner it cuts cannot be sharper than the tool’s radius. A 1/2 inch diameter cutter has a 1/4 inch radius. That simple geometry does not establish the best finishing tool or guarantee a specific minimum radius on every part.

02 /

Avoid matching the cutter exactly when possible

A pocket radius slightly larger than the planned cutter radius can allow a smoother toolpath through the corner. It reduces the abrupt engagement associated with filling the corner using a same-radius tool. The practical allowance depends on the toolpath and finish requirements.

03 /

Square mating parts can still fit

A square component does not always require a square milled pocket. Oversize the pocket where clearance allows, chamfer the mating component, or add corner reliefs outside the functional contact area. A dog-bone style relief changes local geometry and should be deliberately included in the model.

04 /

Depth changes the answer

A tiny corner radius in a shallow recess is different from the same radius at the bottom of a deep cavity. Smaller tools have less rigidity and limited reach. If a deep pocket only needs a small detail near the top, split the geometry so the entire depth does not force that tool size.

Put the design to work.

Choose the process, verify your files, and take the next step toward a custom part.