Printed Electronics & Flexible Hybrid Electronics worked example

Registration Tolerance with achieved layer-to-layer registration accuracy of 310 units: a worked example

What does the result look like when achieved layer-to-layer registration accuracy reaches 310 units? The full calculation is worked below with real intermediate numbers. Use it when registration tolerance in printed electronics and flexible hybrid electronics needs a clean margin number for a printed electronics and flexible hybrid electronics go / no-go review.

The inputs for this scenario

  • Achieved layer-to-layer registration accuracy: 310 units (raised for this scenario; the documented default is 125)
  • Design registration tolerance budget: 100 units (unchanged)
  • Feature or pad reference dimension: 100 units (unchanged)

Working through the calculation

  • Applying the documented formula (Registration Tolerance margin = available value - required value) to the inputs above produces each figure below.
  • At this operating point the engine returns 210 % for margin, the number this scenario is built around.
  • At this operating point the engine returns 210 value for absolute margin.
  • At this operating point the engine returns 310 value for available amount.
  • At this operating point the engine returns 100 value for required amount.

How this compares with the baseline

  • Against the tool's baseline example, where achieved layer-to-layer registration accuracy sits at 125 units and the headline result is 25 %, this scenario comes in 740% above the baseline at 210 %.
  • A figure at this level is achievable when achieved layer-to-layer registration accuracy is genuinely sustained, not just peaked for a shift. It treats registration as a single static value; real webs drift with tension, temperature and machine-direction stretch, so a comfortable static margin can still be eroded by dynamic error across a long roll.

Results at a glance

  • Margin: 210 % (headline result)
  • Absolute margin: 210 value
  • Available amount: 310 value
  • Required amount: 100 value

Run it with your numbers

  • Every input above is editable in the live Registration Tolerance calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.