Tolerance Stack-up Calculator May 2026

: ( Gap = 20.0 - 15.0 - 4.8 - 0.2 = 0.0 ) mm nominal.

1. Overview & Purpose A Tolerance Stack-Up Calculator is an engineering tool used to predict the cumulative variation in an assembly due to the individual tolerances of its components. It answers a critical question: “Given the allowed manufacturing variations in each part, what is the likely total range of variation in the final assembly?” tolerance stack-up calculator

| Component | Nominal (mm) | Tolerance | Direction | |-----------|--------------|-----------|-----------| | Housing depth | 20.0 | ±0.1 | + | | Bushing flange | 15.0 | ±0.05 | - | | Shaft shoulder | 4.8 | ±0.08 | - | | Clip thickness | 0.2 | ±0.02 | - | : ( Gap = 20

: ( T_total = 0.1 + 0.05 + 0.08 + 0.02 = 0.25 ) mm → Gap range = (0.0 \pm 0.25) → fails requirement (( \pm 0.2 ) max). It answers a critical question: “Given the allowed