What is Tolerance Analysis? Why is It Needed? How to Do It?

An introduction to the what, why, and how of tolerance analysis for manufactured products based on mechanisms. Topics covered include:

  • What is tolerance analysis and why is it needed?
  • What products need tolerance analysis?
  • How to do tolerance analysis?
  • What is functional tolerance analysis?
  • What are the benefits?

When to Use 1D, 2D, and 3D Tolerance Analysis?

Learn about 1D, 2D, and 3D stack-up modeling and analysis options, their differences, when to use them, and their tradeoffs for tolerance analysis. Here’s the contents:

  • What is 1D stack-up tolerance analysis?
  • What is 2D stack-up tolerance analysis?
  • What is 3D stack-up tolerance analysis?

What are Worst Case, RSS, and Monte Carlo Stackup Calculation Methods?

Which method(s) to use depends on factors such as how critical a stackup is, how many components, or the complexity of geometries. This article overviews:

  • Worst-case stack-up calculations
  • Statistical stack-up calculations
  • RSS stack-up calculations
  • Monte Carlo simulation stack-up calculations
  • Additional stack-up calculation methods

What is Tolerancing in the Manufacturing Industry?

Measuring a part to ensure if it is within tolerances.

Overviews tolerancing in the manufacturing of mechanical products, Topics:

  • Brief history of tolerancing
  • How are tolerances measured?
  • How are tolerances specified?
  • What is GD&T?
  • GD&T Examples


What is tolerance analysis?

What is GD&T and why is it important?

What are the GD&T symbols? Are they identical in a tolerance analysis software?

Why combining GD&T with physical variations is critical to robustness?


What means CP, CPK and PPM?

OTHER RESOURCES (to be hidden)



What are the statistical calculation methods: RSS, Monte Carlo and their differences with the worst case method?

What is the sensitivity and how does it contribute to design robusteness?

What does analysis of variance tell us?


How to chose the best tolerance analysis software?

What is a Tolerance Management Software?

What is the difference between CAD and CAE?

What is SPC and how does it contribute to continuous design improvement?

What is supplier quality assurance and how an FRM can help?

What is a Functional Relationship Management system FRM?


What is simulation driven design?

What is CAE (and the 3 mains steps in CAE simulation)?

What are the differences between 1D, 2D and 3D tolerance stacks?

What is model based definition and model based enterprise?

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