Printed Electronics & Flexible Hybrid Electronics worked example

Registration Tolerance with achieved layer-to-layer registration accuracy of 63 units: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop achieved layer-to-layer registration accuracy to 63 units, then walk the calculation through step by step. Registration tolerance measures how much headroom you have between the layer-to-layer alignment your press or printer actually achieves and the alignment your design demands.

The inputs for this scenario

  • Achieved layer-to-layer registration accuracy: 63 units (the input this scenario stresses; the baseline uses 125)
  • Design registration tolerance budget: 100 units (held at the documented default)
  • Feature or pad reference dimension: 100 units (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Registration Tolerance margin = available value - required value.
  • Margin works out to -37 % at these inputs, and this is the headline figure for the scenario.
  • Absolute margin works out to -37 value at these inputs.
  • Available amount works out to 63 value at these inputs.
  • Required amount works out to 100 value at these inputs.

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 248% below the baseline at -37 %.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to achieved layer-to-layer registration accuracy, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: -37 % (headline result)
  • Absolute margin: -37 value
  • Available amount: 63 value
  • Required amount: 100 value

Run it with your numbers

  • To rerun this with your own numbers, open the live Registration Tolerance calculator, set achieved layer-to-layer registration accuracy to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.