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Tolerance Stack-Up Calculator

Build, analyze, iterate. Results update live as you edit.

Predict how the tolerances on individual features stack up across an assembly. Build the dimension chain (1D) or hole-alignment pattern (2D) and check the result against spec by worst-case, RSS, and Monte Carlo.

About Tolerance Stack-Up

A tolerance stack-up combines the variation of every part and feature that controls a functional requirement (a gap, a fit, an alignment) to predict whether the assembled result stays within spec. Instead of judging each tolerance in isolation, you add their effects along a dimension chain.

This tool runs two modes: 1D linear stacks (dimensions along a single axis) and 2D hole-alignment / fastener-clearance checks (positional tolerances in a plane).

Three methods, side by side

Worst case sums every tolerance at its extreme: conservative, for safety-critical features. RSS (root-sum-square) treats contributors as independent normal distributions and reports nominal ±3σ, realistic for controlled processes. Monte Carlo simulates 10,000 assemblies from the distribution you assign each contributor and reports the actual yield against spec.

Reference: ASME Y14.5 (GD&T) for the positional-tolerance framework; RSS and Monte Carlo follow standard statistical tolerance-analysis practice. Preliminary / convenience use; verify against your governing spec before design release.

Build Stack

Requirement

Direction
Specification limits
in

Minimum acceptable value.

in

Optional nominal target.

in

Maximum acceptable value.

NameNominal (in)+Tol (in)-Tol (in)SignDistributionActions
Blank tolerances are treated as zero. Invalid rows are skipped.

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