We usually cast agarose gels 3 mm to 4 mm thick. The gel volume needed can easily be estimated by measuring the surface area of the casting chamber, then multiplying by the gel thickness.
Thinner gels can be cast on GelBond™ Support Film, and/or cast in a vertical apparatus.
The thickness of the comb in the direction of the electrical field can also profoundly affect the resolution.
A thin comb (1 mm) will result in sharper DNA bands. With too thick a comb, the separated DNA bands will be quite broad.